Facilities Design and Maintenance | Lecture notes Industrial design

CONCEPT OF FACILITY DESIGN OPERATIONS

Facility design is the planning and designing of physical environment of an activity to best

support the execution of this activity. In other words, facility design attempts to organize

the tangible fixed assets of an activity in such way as to provide maximal support for the

achievement of the activity’s objectives at the present time and in the future at the lowest

possible cost. This activity can take many different forms e.g manufacturing (plant layout),

health care (hospital layout), transportation(air port layout), and services (bank layout)

Important factors to note when selecting a site for facility development.

1. Location : facility location determines the location of production facility to be

designed, this placement is important with respect to customers, suppliers, labour

force and other facilities with which it interfaces. Facility location decisions are often

made by the highest level of management and are based very often on political and

financial considerations.

The type, volume of products to be manufactured or service to be provided,

manufacturing processes required, design of components, type, number of

equipment required and the process planning are the likely problems to be faced

when selecting a location.

2. Material handling layout/devices : this layout shows the block layout of the

departments and the major material handling areas such as aisles and storage

systems, and the location of the interface points between the departments and the

material handling system.

Determining material handling methods, layout of equipment within each cell, layout

of machine cells, determination of machine cells and tooling, fixture determination

are the likely problems to be faced during material handling process.

3. Determining flow of products : this is a process of getting the finished goods to the

final customers. Scheduling and planning of jobs, overall system design, inventory

control, distribution of goods and quality control and customer service are the likely

problems to faced during the service delivery.

CHARACTERISTICS OF A FACILITY DESIGN PROJECT.

Facilities design is a typical engineering design project and as such exhibits the main

characteristics of any (large) engineering design project.

1. Facilities design is a complex problem, the problem is ill defined, the objectives and

constraints are fuzzy. Different people have different definitions and objectives of

the project. Some constraints are implicitly assumed. Hence , there does not exist an

optimal mathematical solutions as in linear programming.

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CONCEPT OF FACILITY DESIGN OPERATIONS

Facility design is the planning and designing of physical environment of an activity to best support the execution of this activity. In other words, facility design attempts to organize the tangible fixed assets of an activity in such way as to provide maximal support for the achievement of the activity’s objectives at the present time and in the future at the lowest possible cost. This activity can take many different forms e.g manufacturing (plant layout), health care (hospital layout), transportation(air port layout), and services (bank layout) Important factors to note when selecting a site for facility development.

Location : facility location determines the location of production facility to be designed, this placement is important with respect to customers, suppliers, labour force and other facilities with which it interfaces. Facility location decisions are often made by the highest level of management and are based very often on political and financial considerations. The type, volume of products to be manufactured or service to be provided, manufacturing processes required, design of components, type, number of equipment required and the process planning are the likely problems to be faced when selecting a location.
Material handling layout/devices : this layout shows the block layout of the departments and the major material handling areas such as aisles and storage systems, and the location of the interface points between the departments and the material handling system. Determining material handling methods, layout of equipment within each cell, layout of machine cells, determination of machine cells and tooling, fixture determination are the likely problems to be faced during material handling process.
Determining flow of products : this is a process of getting the finished goods to the final customers. Scheduling and planning of jobs, overall system design, inventory control, distribution of goods and quality control and customer service are the likely problems to faced during the service delivery. CHARACTERISTICS OF A FACILITY DESIGN PROJECT. Facilities design is a typical engineering design project and as such exhibits the main characteristics of any (large) engineering design project.
Facilities design is a complex problem, the problem is ill defined, the objectives and constraints are fuzzy. Different people have different definitions and objectives of the project. Some constraints are implicitly assumed. Hence , there does not exist an optimal mathematical solutions as in linear programming.

Facilities design is an interdisciplinary team effort. No engineer can do all the work or has all the expertise. Many different groups will be using the facility and have different requirements for the facility. Communication between all user groups and design team is essential for the later acceptance of the facility.
Activities and their supporting facilities change constantly over time and the facilities design project will be redefined accordingly.
The mathematical models for such a complex, fuzzy, and dynamic design problem are very hard to formulate and solve
Most computer algorithms require a clear and precise statement of the problem, objectives and constraints. The facilities design problem does not any of these, so there has been very limited success with the application of computer aided layout programs. FACILITY MAINTENANCE. Facility maintenance means much more than just carrying out a renovation work, but involves the entire administrative and managerial activities required in ensuring that a facility performs its function continuously. According to the British Standard, Maintenance is defined as “ work undertaken in order to keep or restore any part of a building or machinery to an acceptable standard” these acceptable standard are usually set by law. The main purpose of maintenance is to keep a facility in a good and tenantable condition, whereby it can effectively continue serving the purpose for which it was built, and also present a good appearance. In addition, property maintenance is meant to prolong the life span of the property and preserve its value. PURPOSE OF FACILITY MAINTENANCE It is pertinent to outline the reasons why building and machine owners should imbibe a good maintenance culture, some of the reasons are:
Preserve the initial state and good appearance of the facility as far as it is economically viable and practicable, so that it can effectively continue to serve the purpose for which it was designed and built
Ensure that all fixtures and fittings are functioning properly at all times so that the building and machines can sustain its purpose.
Uplift the quality and life of existing facilities, which may have fallen below the accepted standard.
Retain and /or improve the value of investment and make it attractive.
Maintain an acceptance quality standard in terms of the structural stability to meet the current state and demand , and to retain or preserve the aesthetic value.

TECHNIQUES OF MAINTENANCE.

Building obsolescence is inevitable but can be controlled by proper maintenance practices directed towards delaying the deteriorating process for as long as possible and with reasonable cost. It is however a basic understanding of building life cycle, its deterioration pattern and causes of decay. The two type maintenance are :

PLANNED MAINTENANCE : this involves such works undertaken as a protective measure to the property and/or its components. The necessary money required has been included in the total maintenance budget for given period. However, planned, maintenance could be preventive or corrective: i. Preventive maintenance : this refers to the items of work considered necessary to arrest deteriorating or to prevent failure of the building or machine. It is usually carried out within the expected life of the building to ensure continued operation. ii. Corrective maintenance : this involves such works undertaken in order to rectify a defect, or to restore a facility to an acceptable standard. It is usually carried out after a failure has occurred. It is also required to rectify faults or failures caused by incorrect installation or the use of faulty or sub standard materials. Though planned corrective maintenance is reactive in nature, there is a conscious plan of action and budgeting for the necessary works.
UNPLANNED MAINTENANCE : this otherwise known as emergency or ad hoc maintenance, involves such works undertaken to redress unforeseen breakdown, damage or failure of building or machine components. It is essentially reactive in nature because its purpose is to deal with visible defects. No conscious plan of action is prepared beforehand, and its gives little or no room for effective planning and budgeting. Unplanned maintenance can be categorized into two: i. Restoration work: such as re-roofing or rebuilding defective walls, reconstruction of damaged bridge. ii. Routine or day-to-day maintenance such as checking road embankment failure , rainwater gutters and servicing meachanical and electrical installations. Routine maintenance can further be sub- divided into predictable and avoidable, maintenance. Other variants of planned and unplanned maintenance are i. Emergency Maintenance : the maintenance, which is necessary to put in hand immediately to avoid serious consequences this is sometimes referred to as day-to-day maintenance, resulting from such incidents as gas leaks and gale damage.

ii. Condition-based maintenance: preventive maintenance carried out at a predetermined interval of time, number of operations, mileage, e.t.c, it involves regular inspection cleaning, testing, and routine checks regularly. iii. Predictable maintenance : is regular periodic work that may be necessary to retain the performance characteristics of a product as well as that required to replace or repair the product after it has achieved a useful life span. iv. Avoidable Maintenance : is the work required to rectify failure caused by incorrect design, incorrect installation or the use of faulty materials that is substandard/adulterated materials. THE MAINTENANCE PROCESS Maintenance process is the steps taken in improving, or remedying a property in a defective condition. This includes the following : a. Inspection : this is the first step in a maintenance process. It is very vital as it helps the property manager in determining the extent of maintenance works to be undertaken on a property, and how to assign priority to each work. For example, emergency work comes first in a priority list. The property inspection process would include: i. Collection of data by inspection, test interview or discussion with those involve in the design construction, as well as the occupier of the property, so as to identify the defective part of the building elements or equipment. ii. Getting information from drawing specification and other document in regards to the property concerned. iii. Observation by sighting, touching, smelling and testing iv. Use of moisture meter to detect dampness. v. Recording information- construction detail, distinction between a design and building drawing. Materials needed for inspection/accessing maintenance need. The materials with which to access maintenance need depends on the preference of the managing firm, the nature of inspection and type of property involved. b. Compilation and certification of schedule of works Having known the extent of work to be done, the property manager goes ahead to compile the various work to be undertaken. He prepares the schedule of work to be done, itemising the faults in the building or facility, and specifies standard of materials to be used as well as necessary approvals to be obtained. To make this decision, he must not only know the cost implication of the various alternatives, but

D. Identification of competent personnel or contractor. This is the process whereby competent personnel are identified for the job, it may not be an easy task to identify competent personnel as the job to be executed need to be thoroughly understood. This is what will determine who to consider for the job i.e whether direct or a contractor. The process of identification may take the following ways; i. By recommendation : a contractor may be recommended for the job by another party, based on his success in handling such project in the past. ii. A contractor may be identified based on satisfactory performance in previous services rendered to the landlord or the property manager. iii. By tender : contractor may be identified through tendering i.e various contractors submit tender to the project for consideration, and one of them selected for the job at the end after satisfying the client through his tender. iv. By specification: a contractor may be identified for a job based on his degree of specification .i.e having a deep knowledge of the job to be done. v. Nature of the job : type of the job to be executed may determine who should be awarded the project. For example, if it is a job that is, highly technical , a competent and technical contractor will have to be contracted. vi. Direct labour : This is a more efficient and economic way of carrying out maintenance work provided it is adequately controlled and directed. In this method, materials requied for themaintenance works are ordered when the detailed description of maintenance work to be carried out are known, and must be before the maintenance team commence their work on site. Direct labour is particularly well placed to cope with emergency repairs to large commercial and public buildings. On the other hand, the establishment of a direct labour maintenance will require the provision and administration of supporting facilities such as stores, transportation and accounting services, a high standard of supervision and control so as to ensure economic programming, good productivity, quality of work, experience and efficient management to provide effective labour relations and communication.

Contract labour : contract labour account for less than half of all estimated expenditure on the building maintenance. Nevertheless they have in the past constituted the more flexible part being that they are subjected to direct economic pressures and can respond fairly readily to changes in the pattern of demand. Contracts play an important role in maintenance work, both for putting buildings in repair and for larger periodic works. Successful results depend on exacting and well-detailed specifications and close supervision. Special contractors are indispensable for maintenance of lifts and other sophisticated facilities that may be provided in the property. Apart from the above mentioned points, the quality of the contractor may have to be studied and appraised through the followings: i. Financial capabilities, that is, ability to complete the work before payment ii. Specialization in maintenance work and iii. Controlled labour force : the ability to perform, complete and carry out the works according to the programme. E. invitation to tender Invitation to tender is the system of inviting contractors to submit bid for the job to assist the clients or property manager in selecting the best contractor for the job among them, based on their satisfaction given the client through their tenders. Types of tendering A. Open tendering : this involves inviting tender from as many contractors as possible. It does not have a targeted number of tender, and technical experience is not a criteria for this type of tendering. B. Selective tendering : this type of tendering involves selecting a few contractors to bid for the job. This may be as a result of their technical expertise, reputation or the goodwill which the contractors have established overtime. C. Negotiated tendering : this tendering promotes competition. It involves selecting contractors based on their qualities, abilities, and resources. Stages of tendering : there are two stages of tender: pre-tender stage and Tender stage. a. Pre-tender stage : the stage when all the document required for tendering are made available to the

importance to him, but finance he is providing must be deducted from the rest he is to pay. This situation arises when both the client and the property manager are both financially incapacitated. Another way by which a tenant could be involved in financing maintenance work is through the payment of premium. Expansions is the act of increasing (something) in size or volume or quantity or scope (enlargement). the challenges to expanding a food plant i. Space ii. Construction during operation iii. Utilities iv. Labour v. Waste treatment.

ways by which you can overcome the challenges of expansions or expanding a food plant. i. Training of plant and construction workers ii. Physical barriers iii. Scheduling iv. Additional investment in utilities The term sustainability and its importance to facility design and operations Sustainability is now a well-known and commonly accepted framework for guiding a wide variety of choices. Sustainability suggests that, in the decision making process, societies that have a good quality of life have an obligation to ensure both future societies and contemporary, less well off societies are also able to achieve a standard of living in which their basic needs are met. The Whistler 2020 (Canada) sustainable community movement describes sustainability as “… a minimum condition for a flourishing planet in the long term.”1 Communities are applying sustainability to solving energy problems, addressing waste disposal issues, developing green spaces, planning urban areas, and reinvigorating the local economy. Companies are using the concept of sustainability to expand the measure of success for their endeavors from the financial bottom-line to a triple bottom line that adds social and environmental performance to economic performance. According to the Brundtland Report: “..meeting the needs of the present without compromising the ability of future generations to meet their needs. The positive and negative environmental impacts of facility design and operations Positive impacts. i. Environmental awareness ii. Enhancements of local environment iii. Protection and conservation of wildlife iv. It draws attention to issues relating to biodiversity, endangered species and human impact on the environment. v. It helps to increase visitor numbers by improving the general amenity value of the local environment.

Facilities Design and Maintenance, Lecture notes of Industrial design

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Download Facilities Design and Maintenance and more Lecture notes Industrial design in PDF only on Docsity!

CONCEPT OF FACILITY DESIGN OPERATIONS

TECHNIQUES OF MAINTENANCE.