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The Strategos Guide To Value Stream & Process Mapping Facilities Planning & Workplace Design

Warehouse Modernization & Planning Guide The Human Side of Lean Video

The Master Site Plan for Industrial Facilities

Master Site Planning & Development

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Companies often occupy a site for decades and, occasionally, for centuries. During such time spans a firm may experience growth and significant changes in product and process.

A well thought out site plan accommodates such changes while maximizing the utilization of land, buildings and capital. Conversely, a site that develops piecemeal and from expediency hinders operations, increases cost and devours capital unnecessarily.

Effective site plans arise from methodical, rational design procedures. Chapter 6 of Mr. Lee's book, "Facilities and Workplace Design" details these procedures. This book is available as a free download.

While it is impossible to see clearly decades into the future, it is surprising how much we can see and how well we can plan. The key is to develop plans that are flexible enough to take advantage of unforeseen opportunities and address unforeseen problems.

 

Phased Site Planning Example

This example shows how a site for manufacturing vinyl extruded products was planned for a logical four-stage expansion to full capacity.

 

"Prediction is very difficult, especially if it's about the future."

- Niels Bohr (also attributed to Mark Twain and Yogi Berra)

Master Site Plan Example

High Plains Implements

Master Site Plan

The site above provided many planning challenges. Among these challenges: 1) It faces a busy thoroughfare and needs to have a good image. 2) Residential areas to the North require consideration. 3) The land slopes significantly and a stream runs through it.

One might well criticize the original selection of this site. However, like many sites, it was a given and the designers had to work with it.

The site plan reflects an explicit Manufacturing Strategy. Some of the key points that affected site planning were: 1) Separate Strategic Business Units (SBU) for Foundry, Machine Shop, Spares and the two Assembly Operations. 2) A separate, small Corporate Headquarters. 3) Significant seasonal inventories for Implements. 4) Consideration for the image and needs of neighbors.

References

LEE, QUARTERMAN, Facilities & Workplace Design, Engineering & Management Press, Norcross, Georgia, 1997.

SKINNER, WICKHAM, The Focused Factory, Harvard Business Review, May-June, 1974.

WRENNALL, WILLIAM, AND LEE, QUARTERMAN, Handbook of Commercial and Industrial Facilities Management, McGraw Hill, August, 1993.

PHILLIPS, EDWARD J., Manufacturing Plant Layout: Fundamentals and Fine Points of Optimum Facility Design, Society of Manufacturing Engineers, Dearborn, Michigan, USA, 1997.

"No plan survives contact with the enemy."

Helmuth von Moltke

(The Elder)

 

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