facility layout and location - industrial engineerin

Page 1 of 6 ISE 422 Term Project Syed & Nahas

Poblix Inc., a well-known financing company in the retail business industry, is planning to open new chain of malls named “moondinar” in the Republic of Utopia. The chain of malls that they plan to start, typically serves the local residential communities. The company’s Research & Development team identified that a successful shopping mall should be comprehensive enough to cater all the needs of the residents. The company targets that the store will become the primary choice for food, clothing, accessories (fashion, jewelry), electronic, cinema, and toys/kids for the community. Thus, the major stores in the mall will fall into the above categories. Furthermore, the mall should have smooth mobility for the customers and balance of workload for the mall services. The mall will not only be used for the next fiscal year, but also for the future years as well. Perhaps, the mall should be flexible to withstand changes for the next 30 to 40 years without any major changes. They are looking for Industrial Engineers (IEs) to design the manufacturing facility, and to locate the similar facilities across the republic. Your team is hired by the company as IE consultants to achieve the following two major tasks: 1. Design the layout of the shopping mall (Block and Detailed) 2. Provide the locations for the shopping mall Relevant data and details are provided in the following pages of the document. Since the company is unaware of the methodologies that you will be using to design the facilities, you are allowed to make reasonable assumptions for the missing data. You are expected to use the standards wherever applicable. Your goal is to provide the company with the best layout and the locations for the facility.

Project No: ISE01720422

Start Date: Apr 14, 2018

Due Date: May 14, 2018

Page 2 of 6 ISE 422 Term Project Syed & Nahas

THE SHOPPING MALL

The company focuses on the layout of a new mall (Moondinar mall) that will be built in the college town, at the intersection of University Avenue and 20th street. The location is the prime shopping location, and serves the entire community. Poblix owns many malls in the other countries, and they plan to build the new chain of malls in the Republic of Utopia. The company has conducted an extensive data collection in their existing malls. In addition to that, the leading economic indicators, and surveys were used to identify potential list of stores/restaurants/services (from here onwards, they will be called as entity). The entities that will be launched in the mall are listed in Table-1:

Table-1: Entities and Corresponding Type Entity* Type Entity Type

Accessorize Accessories Peacocks Clothing

Claire's Accessories Reiss Clothing

Clarks Accessories River Island Clothing

Fossil Accessories Simply Be Clothing

Glamour Forever Accessories Apple Electronics

Goldsmiths Accessories Bose Electronics

Kiko Milano Accessories MenKind Electronics

MAC Accessories Virgin Media Electronics

Michael Kors Accessories Café Rouge Food

Miss Diva Shoes Accessories Caffè Nero Food

Monsoon Accessories Costa Coffee Food

Pandora Accessories Gourmet Burger Food

Shoe Zone Accessories Krispy Kreme Food

Swarovski Accessories Muffin Break Food

Swatch Accessories Nando's Food

The Body Shop Accessories Nespresso Food

The Pen Shop Accessories PizzaExpress Food

The Perfume Shop Accessories Starbucks Food

Vision Express Accessories TGI Fridays Food

Watches of Switzerland Accessories Yo! Sushi Food

L'Occitane Accessories Zizzi Food

Lovisa Accessories Mount Fuji Food

Radley Accessories Nata & Co Food

Ernest Jones Accessories Prezzo Food

Bonmarche Clothing Shake Shack Food

Crew Clothing Co. Clothing Card Factory Gifts

Debenhams Clothing Hawkins Bazaar Kids

Fat Face Clothing Build a Bear Kids

Gap Clothing Disney Kids

H&M Clothing Game Kids

Hollister Clothing Hamleys Kids

New Look Clothing Kids around Kids

Quiz Clothing Clothing Lego Store Kids

Timberland Clothing Cineworld Movie

Moss Bros Clothing Foot Locker Shoes

Oasis Clothing Sports Direct Sports

In addition to the list of entities that will be placed inside the mall facility. Auxiliary facilities like parking** and entrance/exits should also be considered. The available space to build the mall and the parking is shown in Figure-1. *The brands are named here for educational purpose. It is not for any profitable or non-academic reasons. ** The space required for parking can be estimated based on the information in Section 1.3.

Page 3 of 6 ISE 422 Term Project Syed & Nahas

Following is the top view of the available land that will be used to build the mall. The management would like you to consider the accessibility to the roads while building the layout. The green colored area indicates no access to road. The black colored area indicated access to road. The brown color area indicates the available space. The red and blue colored area indicates unusable space. All the distances in given in meters.

Figure-1: Available space for Moondinar

LAYOUT ANALYSIS

The focus of this section is to develop the block and detailed layout of the Moondinar mall. Following subsection highlights the necessary information. Assume any further relevant information and design the block and the detailed layouts.

1.1 MALL BL OCK A SS IGNMENT S:

The overview of various available blocks, unavailable blocks, aisle and gates is displayed in Figure-2. The aisle, unusable blocks, and gates arrangement cannot be changed. The first stage of this project is to assign blocks to different entities. The blocks are rented or purchased by each entity, based on their requirements and budget. The number of blocks per entity is assumed to be one. Based on the historical data from the entities and the company, the expected demand per day for each entity is given in the excel sheet titled DEMAND in the excel workbook named Data-xx. xlsx, where “xx” stands for your group number. There are four segments (A, B, C, D) in the mall. All the entities must be organized such that the overall number of customers in each segment is balanced. That is, the total demand in each segment should similar to the other segments. Only block starting from A are part of segment A. Also, only the four segments (A, B, C, D) should be balanced. The block numbers starting from “F” must be assigned to food type entities. The block numbers starting from “G” should be assigned to food and kids type entities only. Preference is given to the food type entities only.

1000 mts

650 mts

80

120 150

150

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Figure-2: The Internal Layout of the Moondinar Mall

1.2 DEBENH AMS BL OCK L AYOUT:

The estimated flow in number of customer units for the Debenhams are given in the excel sheet titled FLOW in the excel workbook named Data-xx. xlsx. The following table provides the information regarding the space requirements for various departments:

Table-2: Space requirements of the Debenhams entity

Department Name Area (m2)

Department Name Area (m2)

1 Department-1 2 11 Department-11 4

2 Department-2 8 12 Department-12 2

3 Department-3 3 13 Department-13 3

4 Department-4 4 14 Department-14 1

5 Department-5 4 15 Department-15 1

6 Department-6 1 16 Department-16 7

7 Department-7 1 17 Department-17 4

8 Department-8 5 18 Department-18 3

9 Department-9 3 19 Department-19 3

10 Department-10 2 20 Department-20 2

600 mts

600 mts

Page 5 of 6 ISE 422 Term Project Syed & Nahas

Using the above data, construct a block layout for the Debenhams entity. The total area for Debenhams block is 80 sqmts (8 mts x 10 mts).

1 .3 DET AILED LAY OUTS

Parking: All the employees and the customers working at the firm needs car parking. Management would like

to have two types of parking areas. Parking area-1 will be a 45𝑜 inclined parking, which will be used by the customers. Parking area-2 will be perpendicular parking, which will be used by the employees. Management has projected that on an average there will be 500 people working in the mall services. A rough

breakdown of the employees will be: 𝑁(300,20) at the cleaning worker level, 𝑁(100,10) at the supervisor & security level and 𝑁(50,5) at the higher management level. It is estimated that 50% of the employees will be using bus transportation system, and may not be needing the parking. However, a bus parking should be available for those employees. In addition to that, the plant will maintain some official vehicles (80 pickups, 20 sedans, 10 bikes, and 5 SUVs) for the day to day works at the plant. Once an employee starts his/her day at the plant, he/she will be using the plant official vehicles for all the official transportations. It is also estimated that the number of customers during weekdays will be

𝑁(1000,200) and the number of customers during weekends will be 𝑁(3000,500). Figures-3a & 3b display the difference between inclined and perpendicular parking. Assume necessary

information, and identify the appropriate space for the canteen. Note: 𝑁(0,1) represents a normal distribution with mean 0 and variance 1.

Figure-3a: Perpendicular Parking Figure-3b: Incline Parking

LOCATION ANALYSIS

The major task in this domain is to identify the locations of the shopping mall and distribution centers. The management has identified potential docks that will be used by its suppliers to send the goods to the mall. In addition to that, the management has identified potential customer zones in the country. The objective is to use the information of supplier and customers in identifying the location of the mall, and the locations of the distribution centers (see Figure-4). The management is planning to open at most 10 malls, and up to 3 distributions centers. The distributions centers can be built on any site, however, the malls can only be built only on the available sites. The coordinates of the potential docks are given in the worksheet title COORDINATES in Data-xx. xlsx workbook. The cover data of available sites and customers are given in the worksheet titled SITES in Data- xx.xlsx. The management would like to maximize the percentage of customers they can cover, for a given number of malls. That is, they would like you to provide them with a graph of number of malls that are built on the x-axis, and the percentage of customers covered on the y-axis. Assume that the cover distance is

𝑁(10,5) K.m.

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Figure-4: Location Planning

S U

P P

L IE

R S

(1) DISTRIBUTION CENTER

(up to 10)

SHOPPING MALLS

C U

S T

O M

E R

S