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ISEN 416. Facility Location, Layout and Material Handling

Description: Analytical treatment of facilities location, physical layout, material flow and handling, combined with heuristics algorithms to assist in the design of production/service facilities; fundamental concepts applied through a sequence of design projects.

PREREQUISITES

ISEN 315; ISEN 316 or registration therein. For ENTC students the prerequisites are ENTC 181, ENTC 412, and ISEN 302.

COURSE OBJECTIVES

(1) Learn formulations, models, and analytical procedures for the study of facilities layout planning. (2) Learn fundamental principles of material handling. (3) Be able to design a factory layout incorporating product, process, and personnel requirements. (4) Improve presentation & team working skills

TEXTBOOK AND ADDITIONAL COURSE MATERIAL

A. FACILITIES PLANNING by Tompkins et al., Third Edition, John Wiley & Sons, 2003.
B. Reading Guide by A. Garcia-Diaz, Available at G:\classes\Garcia\ISEN416\rguide.
C. Laboratory Handbook by A. Garcia-Diaz, Spring 2003.

TOPICAL OUTLINE

Topics to be covered in the lectures:

1. Concepts of manufacturing and facilities planning.
2. Strategic facilities planning.
3. Product, process, and schedule design.
4. Activity relationships and space requirements.
5. Process for developing layout alternatives.
6. Overview of computer-aided layout procedures.
7. Material handling: principles, equipment and analytical procedures.
8. Personnel requirements (reading assignment).
9. Office layout planning.
10. Location models in facilities planning.
11. Receiving and shipping functions.
12. Storage and warehousing: principles and models.

Laboratory Design Project

Section 1: production drawings, part drawings, parts identification
            Section 2: production routings, machine requirements & costs, production schedule, material costs
            Section 3: layout planning charts, machine drawings, material handling requirements, handling costs
            Section 4: personnel requirements, personnel costs, unit costs
            Section 5: office layout
            Section 6: plant layout, computer output, illustration of analytical procedures, final report

CLASS SCHEDULE

Lectures: Two days a week, 50 minutes per day.
Lab: Two sections (up to 32 students per section); 150 minutes a week for each section.

PROFESSIONAL COMPONENT

This course provides fundamental concepts, theory and procedures for the study of facilities location, physical layout, material flow, and material handling. Analytical procedures are developed to enhance the decision-making process in the design, rationalization and improvement of manufacturing or service facilities. The knowledge learned in this course will be integrated with knowledge from selected related courses to develop a laboratory design project. Knowledge acquired in ISEN 303, 315, 316, 420, 424, and ENTC 200, along with the student's creativity and ability to apply this material will be of fundamental importance to succeed in this course.

PROGRAM OUTCOMES

A.      An ability to apply knowledge of mathematics, science, and engineering.

Specialized knowledge and analytical procedures are developed to enhance the decision-making process in the design, rationalization and improvement of manufacturing or service facilities. Specific topics of ISEN 416 in which knowledge of mathematics, science and engineering is applied are: (1) Break-even point comparison of layouts. (2) Depreciation analysis of manufacturing and material handling equipment. (3) Manufacturing processes: description, selection, and applications. (4) Calculation of machine and manpower requirements. (4) Flow analysis.

B.      An ability to design a system, component, or process to meet desired needs.

The steps of the scientific method can be reformulated as follows when we consider specifically the engineering design process: (1) define the problem; (2) analyze the problem; (3) generate alternative designs; (4) evaluate the alternatives; (5) select the preferred design; and (6) implement the design.

C.      An ability to function on multi-disciplinary teams.

Students are required to design a plant layout for the production of a mechanical device. In order to promote the team approach, groups of three to four students are allowed for each project. The selection of the device is up to the students, although it requires the approval of the instructor.   The following disciplines are integrated into the design project: (1) Manufacturing processes. (2) Production analysis and control. (3) Material handling. (4) Operations research. (5) Computerized layout design. (6) Management. (7) Marketing. (8) Engineering economy.

D.   An ability to identify, formulate, and solve engineering problems.

ISEN 416 emphasizes on the importance of the following three functions of industrial engineering: (1) product design, (2) process planning, (3) schedule design. Specific formulations studied in this course are: (a) analytical procedures for conveyor analysis in material handling, (b) location and allocation models in facilities planning, (c) storage and warehousing: layout and automated s/r systems models.

E.   An ability to communicate effectively.

The overall project process is divided into six sections, each one requiring a report to be reviewed and graded. After each section report is returned, with specific suggestions and recommendations, each team must revise it effectively to reflect those improvements identified in the review process.

Report 1: production drawings, part drawings, parts identification
Report 2: production routings, machine requirements & costs, production schedule, material costs
Report 3: layout planning charts, machine drawings, material handling requirements, handling costs
Report 4: personnel requirements, personnel costs, unit costs
Report 5: office layout
Report 6: plant layout, craft output, illustration of analytical procedures, summary, conclusions and recommendations

Each team makes a project presentation with specific areas presented by designated members of the group. The guidelines shown below are for project teams consisting of 4 members. For teams consisting of 3 members, sections are properly redistributed. The presentation takes approximately 25 minutes per team, including questions (about 5 minutes). First presenter does introduction to project and Section I. Second one presents Section II, III. Third one presents Section IV, V. Fourth one presents Section VI, Summary, Closing.

F.         A recognition of the need for, and an ability to engage in life-long learning.

Throughout the development of the class, with lecture time devoted to specifically discussing them, the following factors are emphasized as being relevant in the design of modern manufacturing layouts. All these factors are dynamic in nature and allow the students to recognize the importance of being life-long learners, particularly since the factors are present in a number of open-end problems that must be addressed in real-life applications.

G.      An ability to use the techniques, skills, and modern engineering tools necessary for engineering practice.

The following techniques, skills and tools are studied and used: AutoCAD, Computerized layout procedures, Manufacturing strategies, Information-based manufacturing technology, Optimization procedures.

Course info in pdf format

PREPARED BY: Alberto Garcia-Diaz                                           DATE: 9-16-03