06 Facility Location
06 Facility Location
One of the key features of a conversion process (manufacturing system) is the efficiency with which
the products (services) are transferred to the customers. This fact will include the determination of
where to place the plant or facility. The selection of location is a key-decision as large investment is
made in building plant and machinery. It is not advisable or not possible to change the location very
often. So an improper location of plant may lead to waste of all the investments made in building
and machinery, equipment.
Existing organizations become involved in location decisions for variety of reasons. Firms such as
banks, fast food chains, supermarkets, and retail stores view locations as part of marketing strategy,
and they look for locations that will help them expand their markets. Basically, the location decisions
in those cases reflect the addition of new locations to an existing system.
A similar situation occurs when an organization experiences a growth in demand for its products or
services that cannot be satisfied by expansion at an existing location. The addition of a new location
to complement an existing one is often a new location to realistic alternative. Some firms face
location decision through depletion of basic inputs. For example, fishing and logging operations are
often forced to relocate due to the temporary exhaustion of fish and forest at a given location. Mining
32 / PRODUCTION AND OPERATIONS MANAGEMENT
and petroleum operations face the same sort of situation, although usually over a longer horizon. For
others firms, a shift in markets causes them to consider relocation, or the costs of doing business at a
particular location reach a point where other locations begin to look more attractive
There are two primary reasons that location decisions are a highly important part of production
system design.
• One is that they entail a long-term commitment, which makes mistakes difficult to
overcome.
• The other is that location decisions often have an impact on investment requirements,
operating costs and revenues, and operations itself.
For instance a poor choice of location might result in excessive transportation costs, a shortage of
qualified labor, loss of competitive advantage, inadequate supplies of raw materials, or some similar
condition that is detrimental to operations. For services, a poor location could result in loss of
customers and/or high operating costs.
Before a location for a plant is selected, long range forecasts should be made anticipating future
needs of the company. The plant location should be based on the company’s expansion plan and
policy, diversification plan for the products, changing market conditions, the changing sources of
raw materials and many other factors that influence the choice of the location decision. The purpose
of the location study is to find an optimum location one that will result in the greatest advantage to
the organization.
Location decisions for many types of business are made frequently, but they tend to have a
significant impact on the organization. Here we shall look at the nature of location decisions, the
usual objectives managers have when making location choices, and some of the options that are
available to them. Manager can consider four options in location planning.
a) One is to expand an existing facility. This option can be attractive if there is adequate room
for expansion, especially if the location has desirable features that are not readily available
elsewhere. Expansion costs are often less than those of other alternatives.
b) Another option is to add new locations while retaining existing ones, as is done in many
retail operations. In such cases, it is essential to take into account what the impact will be on
the total system. Opening a new store in a shopping mall may simply draw customers who
already patronize an existing store in the same chain rather than expand the market. On the
other hand, adding locations can be a defensive strategy designed to maintain a market share
or to prevent competitors from entering a market.
c) A third option is to shut down at one location and move to another. An organization must
weigh the costs of a move and the resulting benefits against the costs and benefits of
remaining at the existing location. A shift in markets, exhaustion of raw materials, and the
cost of operations often cause firms to consider this option seriously.
d) Finally, organizations have the option of doing nothing. If a detailed analysis of potential
locations fails to uncover benefits that make one of the previous three alternatives attractive,
a firm may decide to maintain the status quo, at least for the time being.
FACILITY LOCATION & LAYOUT PLANNING CHAPTER - 3 33
1. Development of the major objectives of the firm necessitating location selection by the
management.
2. Isolation of pertinent variables affecting the choice of location.
3. Development of accurate and timely information on each of the variables selected in step 2
4. Design for the location system with detailed timetable for implementation.
5. Completing the location move in an effective and efficient manner by review, testing and
feedback control.
With view of cost and system analysis of the organization qualitative and quantitative analysis is
associated. The behavioral aspects of location play influencing role for success of business. For the
selection of location behavioral aspects of each alternative location should be considered. Following
are some behavioral aspect affecting location decision.
(a) Consumer’s Consideration: Customers are the key to success of an organization. Due to this
reason consumers’ behavior should be focused for location decision to fulfill their satisfaction. In
other words, the location decision should be made to convince their interest, accessibility and
convenience regarding location.
(b) Cultural difference: Culture of society reflects the attitude of people. Since, the culture directly
affects the performance of business activities; production manager should have awareness about
the maintenance of good relationship with the society. It is not necessary to establish a business
in a certain location rather transformation of infrastructure, culture and custom in that location
counts a lot. Thus, cultural variations, economic condition of the society affect the location
decision of the management.
(c) Job satisfaction: The reaction upon job itself is the job satisfaction. The satisfaction of needs of
the worker regarding their work is job satisfaction. It is perception regarding satisfaction of
needs. Hence, it also affects the organizational operation. To ensure the job satisfaction,
employees of the organization show the following attitudes like less absenteeism, motivation,
efficiency, less delay and less labor grievance etc. The prosperity of location determines the
value and attitude of labors. So, management finds variations in job satisfaction in various
locations because of different values and attitudes.
no loss. Under this method, the selection of location depends upon the capacity of producing
goods and services of organization.
Y
Sales
Cost & Revenue
TC (Ktm)
BEP (Brj)
E TC (Brj)
BEP (Ktm)
X
O Q1 Q2 Q3
Output in units
As per the above diagram, BEP at Kathmandu can be obtained with lower units of production
compared to Birgunj. So in short run, Kathmandu may be the better alternative without
considering production capacity of the organization. Again 'E' is the equilibrium point of cost
for both locations on which OQ3 units of Output can be produced on both locations at same
very cost.
If the organization has greater capacity for producing more than OQ3 units, then "Birgunj"
should be selected in order to minimize total production cost and vice – versa.
(c) Transportation Technique: It is quantitative method for making decision about the facility
location. This model is more appropriate for large manufacturing concerns which produce
physical goods in massive scale. Once the company produces goods, then the goods should
be delivered to the final consumers and in order to deliver the physical goods to the final
consumers, company requires warehouses in different places. Transportation technique
helps the Operations manager to select the best location for warehouse which can minimize
the transportation cost during the delivery period from origin to destination. Under
transportation technique, we create a cost matrix with equal level of demand and supply of
physical goods. Then initial allocation table should be constructed and made some efforts for
obtaining optimum solution. The process of obtaining optimum solution leads to select best
location which minimizes the total transportation cost.
(d) Central Gravity Technique: This method suggests that particular location which increases
the welfare of consumer at all. The plant of the company should be centrally located on
which majority of the consumers find optimal distance. Central gravity method also stands
with the positive view of employees of organization. The travelling distance for employee
and suppliers as well should be optimum. The major objective of central gravity method is
to search vicinity (neighborhood) point for the optimal locations.
EXERCISE – 6
1. What do you mean by location decision?
2. What steps are required in planning facility location?
3. Describe the quantitative models for facility location.
4. Write down the procedures for facility location planning.
5. Discuss various types of quantitative and qualitative techniques used in facility location
decision.
6. Discuss the impact of behavioral aspect in facility location decision?
7. What are the affecting factors of location decision?
FACILITY LOCATION & LAYOUT PLANNING CHAPTER - 3 41
8 . A newly formed firm must decide on a plant location. There are two alternatives under
consideration: locate near the major raw materials or locate near the major customers. Locating
near the raw materials will result in lower fixed and variable costs than locating near the
market, but the owners believe there would be a loss in sales volume because customers tend to
favor local suppliers. Revenue per unit will be $185 in either case. Using the following
information, determine which location would produce the greater profit.
Omaha Kansas City
Annual fixed costs ($ millions) $1.2 $1.4
Variable cost per unit $36 $47
Expected annual demand (units) 8,000 12,000
9. The owner of Genuine Subs, Inc., hopes to expand the present operation by adding one new
outlet. She has studied three locations. Each would have the same labor and materials costs
(food, serving containers, napkins, etc.) of $1.76 cents per sandwich. Sandwiches sell for $2.65
each in all locations. Rent and equipment costs would be $5,000 per month for location A, $5,500
per month for location B, and $5,800 per month for location C.
a. Determine the volume necessary at each location to realize a monthly profit of $10,000.
b. If expected sales at A, B, and C are 21,000 per month, 22,000 per month, and 23,000 per
month, respectively, which location would yield the greatest profits?
10 . A small producer of machine tools wants to move to a larger building, and has identified two
alternatives. Location A has annual fixed costs of $800,000 and variable costs of $14,000 per unit;
location B has annual fixed costs of $920,000 and variable costs of $13,000 per unit. The finished
items sell for $17,000 each.
a. At what volume of output would the two locations have the same total cost?
b. For what range of output would location A be superior? For what range would B be
superior?
11 . A company that produces pleasure boats has decided to expand one of its lines. Current
facilities are insufficient to handle the increased workload, so the company is considering three
alternatives, A (new location), B (subcontract), and C (expand existing facilities).
Alternative A would involve substantial fixed costs but relatively low variable costs: fixed costs
would be $250,000 per year, and variable costs would be $500 per boat. Subcontracting would
involve a cost per boat of $2,500, and expansion would require an annual fixed cost of $50,000
and a variable cost of $1,000 per boat.
a. Find the range of output for each alternative that would yield the lowest total cost.
b. Which alternative would yield the lowest total cost for an expected annual volume of 150
boats?
c. What other factors might be considered in choosing between expansion and subcontracting?
12 . Rework Problem 4 b using this additional information: Expansion would result in an increase of
$70,000 per year in transportation costs, subcontracting would result in an increase of $25,000
per year, and adding a new location would result in an increase of $4,000 per year.
13 . A firm that has recently experienced an enormous growth rate is seeking to lease a small plant
in Memphis, TN; Biloxi, MS; or Birmingham, AL. Prepare an economic analysis of the three
locations given the following information: Annual costs for building, equipment, and
42 / PRODUCTION AND OPERATIONS MANAGEMENT
administration would be $40,000 for Memphis, $60,000 for Biloxi, and $100,000 for Birmingham.
Labor and materials are expected to be $8 per unit in Memphis, $4 per unit in Biloxi, and $5 per
unit in Birmingham. The Memphis location would increase system transportation costs by
$50,000 per year, the Biloxi location by $60,000 per year, and the Birmingham location by
$25,000 per year. Expected annual volume is 10,000 units.
14 . A retired auto mechanic hopes to open a rustproofing shop. Customers would be local new-car
dealers. Two locations are being considered, one in the center of the city and one on the
outskirts.
The central city location would involve fixed monthly costs of $7,000 and labor, materials, and
transportation costs of $30 per car. The outside location would have fixed monthly costs of
$4,700 and labor, materials, and transportation costs of $40 per car. Dealer price at either
location will be $90 per car.
a. Which location will yield the greatest profit if monthly demand is (1) 200 cars? (2) 300 cars?
b. At what volume of output will the two sites yield the same monthly profit?
15. Using the following factor ratings, determine which location alternative (A, B, or C) should be
chosen on the basis of maximum composite score.
Location Score
Factor(100 points each) Weight A B C
Convenience .15 80 70 60
Parking facilities .20 72 76 92
Display area .18 88 90 90
Shopper traffic .27 94 86 80
Operating costs .10 98 90 82
Neighborhood .10 96 85 75
16. Determine which location has the highest composite score:
Factor Weight East #1 East #2 West
Initial cost 8 100 150 140
Traffic 10 40 40 30
Maintenance 6 20 25 18
Dock space 6 25 10 12
Neighborhood 4 12 8 15
17. A manager has received an analysis of several cities being considered for a new office complex.
The data (10 points maximum) are as follows:
Location Score
Factor A B C
Business services 9 5 5
Community services 7 6 7
Real estate cost 3 8 7
Construction costs 5 6 5
Cost of living 4 7 8
Taxes 5 5 4
Transportation 6 7 8
FACILITY LOCATION & LAYOUT PLANNING CHAPTER - 3 43
a. If the manager weights the factors equally, how would the locations stack up in terms of
their composite factor rating scores?
b. If business services and construction costs are given weights that are double the weights of
the other factors, how would the locations stack up?
18. A toy manufacturer produces toys in five locations throughout the country. Raw materials
(primar-ily barrels of powdered plastic) will be shipped from a new, centralized warehouse
whose loca-tion is to be determined. The monthly quantities to be shipped to each location are
the same. A coordinate system has been established, and the coordinates of each location have
been determined as shown. Determine the coordinates of the centralized warehouse.
Location (x,y)
A 3,7
B 8,2
C 4,6
D 4,1
E 6,4
19. A clothing manufacturer produces women’s clothes at four locations in Mexico. Relative
locations have been determined, as shown in the table below. The location of a central shipping
point for bolts of cloth must now be determined. Weekly quantities to be shipped to each
location are also shown in the table. Determine the coordinates of the location that will
minimize distribution costs.
Location ( x,y) Weekly Quantity
A 5,7 15
B 6,9 20
C 3,9 25
D 9,4 30