ADVANCED PRODUCTION

SYSTEM DESIGN

Prof. Dr. Dr.-Ing. Yilmaz Uygun

Chapter 05
Chapter 5
SPACE REQUIREMENTS

Chapter 05 Advanced Production System Design Page 2

HIERACHIES OF SPACE REQUIREMENTS

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SPACE – TYPES AND PROPERTIES
Types of Spaces Potential Space Properties

• Storage area • Lighting properties

Types and Properties

• Transportation area • Temperature

• Handling area • Soil bearing capacity
• Office space • Clearance
• Recreational area • Safety (theft)
• Buffer zones • Fire protection
• … • Expandability
• Range of use (flexibility)
• …

Network Facility System

• Storage areas • Storage areas • Buffer zones
• Handling areas • Recreational areas • Storage areas
Examples

• … • Office spaces • Picking areas

• … • Transportation areas
• …

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FACILITY-LEVEL SPACE REQUIREMENTS

4 5

1 Administration
3 2 3 4 2 Recreational areas
3 Parts delivery / shipping
4 External area
6 2 5 Parking lot
6 Manufacturing shop floor

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TYPICAL FLOOR SPACE IN A MANUFACTURING FIRM

Work Prep.
Adminis- Area 5%
tration
15% Manu-
Facturing
Area
Shop Floor =
Usable Machines
Space 50%
75% Production 50%
Gross
Total Floor 50%
Floor Space
Space Transport
95% Coating
10%
100% & Logistics
20%

Warehouse Assembly
Utilities WIP 20%
20% 25%
15%
Supporting
Functional 5% areas Additional
15% Other
Construct. 5% Social 5% 10% 10%

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 SYSTEM-LEVEL SPACE REQUIREMENTS

Main Functional Areas:

• Production space
• directly relevant logistics and storage areas
• supporting and other spaces, such as production control, quality control, packaging, etc.

Main Functional Area: AMF = AM + AWIP + AT + AQ + AF [m2]

AM = total space of machine
AWIP = WIP area
AT = transportation area
AQ = quality control area
AF = free area

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TOTAL SPACE OF MACHINES (AM)

Functional areas of a work station

e.g. CNC Lathe

6 5

1
3

1 Machine footprint Mfi

2 Operator´s area AOpi Calculation of Total Space of Machines

3 Material supply area AMati n

AM = ∑AMi
i=1
4 Tool supply area ATi
AMi = Mfi + AOpi + AMati + ATi + AMi +ASi
5 Maintenance area AMi

6 Area for scrap ASi

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TOTAL SPACE OF MACHINES (AM) – SPACE
COEFFICIENT FOR MACHINE FOOTPRINT

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 WIP AREA (AWIP)

Calculation of WIP area

AWIP = 0.2 * AM

Condition:
§ Handling of material in bins
§ Piling up to 3 bins
§ Transportation with fork lifts, cranes, etc.

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 TRANSPORTATION AREAS (AT)

Calculation of Transportation Area

AT = (0.2 ... 0.3) * AM

Condition:
§ Path width 2.5 – 3.0 m

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 QUALITY CONTROL AREA (AQ)

Calculation of Quality Control Area

AQ = 0.13 * AM

Condition:
§ 25% - 35% of parts in quality control work places
§ Rest in self-control

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 FREE AREA (AF)

Calculation of Free Area

AF = 0.18 * AM

Examples:
§ Building restrictions (pillars, etc.)
§ Shop floor management
§ Terminals
§ Disposal areas

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 FLOOR CHARACTERISTICS

Surface Installation

1 Load-bearing capacity 1 Power

2 Durability 2 Phone connection
3 Evenness 3&4 HVAC
4 Slipperiness 5 Clear installation hight
5 Easiness to clean

Construction Physics Elements

1 Thermal insulation
2 Tightness
3 Fire protection 1 Dimensional system
4 Noise protection 2 Mounting plates
5 Discharge capability 3 Construction joints
4 Rearrangement effort

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CONSTRUCTION SHAPES

Shape of the Bulding

Construction Type Shape

Construction Form

Compact (closed)
Hall
U - Shaped
Adminis-
Produktion
Manufacturing Park-
tration
ing -
lot
Catering Warehouse
Single-storey
Building Spine

Loosened (open)
Multi-storey
Adminis-
Building tration Production
Produktion Ring
Park-
ing lot
Catering Warehouse

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HALL

§ Full flexibility
§ Scalability (horizontally & vertically)
§ No special equipment for material flow
§ Easy installations of machines
§ Heavy machinery and goods
§ Good overview of shop floor processes

§ Extensive space requirements

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SINGLE-STOREY BUILDING

§ High flexibility
§ No special equipment for material flow
§ Easy installations of machines
§ Heavy machinery and goods
§ Good overview of shop floor processes
§ Extensive use of sunlight possible
§ Additional installations on roof

§ Extensive space requirements

§ Limited scalability

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MULTI-STOREY BUILDING

§ Efficient use of given space

§ Lightweight machines and products
§ Additional installations on roof possible

§ Low flexibility
§ No scalability
§ Complicated installations of machines
§ Special equipment for material flow
§ Hardly overview of shop floor processes

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GENERAL TYPES OF LAYOUT

Characteristics Principle Structure

U-Shaped E F G H
• U-shaped material flow with logistics and
D
dispatch area at the center
• Feasible with centralized logistics concept
C B A

Ring
A
• Coupling of different areas B
• Functioning of those areas only possible
F
through true ring structure
• Challenge for projects that are realized C E
sequentially D

Spine
• Supporting (material supply) and processing C B A H
(manufacturing) areas

• Possibilities for expansion:

• Macro expansion (extension of the
spine)
• Micro expansion (extension of F E D
manufacturing areas)

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U-SHAPED LAYOUT

§ Efficient use of given space

§ Lightweight machines and products
§ Additional installations on roof possible

§ Low flexibility
§ No scalability
§ Complicated installations of machines
§ Special equipment for material flow
§ Hardly overview of shop floor processes

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COMBINATION OF SHAPES

2. Closing u-shaped vertebrae

to form rings
Initial structure:
Spine

1. Replacing vertebrae by U-shapes

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EXERCISE

§ Calculate the space requirements for the needed machines

§ Use spreadsheets S15 & S16

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THANK YOU!