For undergraduate courses in facilities planning and material handling. Based on ten years' teaching experience, this text takes a practical, teachable approach to facilities planning and design. A class design project centered on a factory incorporates the theoretical aspects of facilities planning and design. Motivating and illustrating mathematical models wherever possible, the text explores facilities planning, capstone design, and even simulation modelling.
Fundamental Principles of Facilities Planning and Design 1.1 Introduction What is Design Characteristics of Design Problems Design Program Design Process1.2 Hierarchical Cycle of Facilities Planning1.3 Objectives of Facilities Planning Issue-Based Information Systems Site-Planning IBIS Example Decision-Support (DSS) Computer Programs1.4 Mathematical Models in Facility Planning1.5 Manufacturing Systems Concepts1.6 Types of Basic Manufacturing Layouts Fixed-Position Layout Product Layout Process Process Layout Process Cellular Layout Process1.7 Service Systems1.8 Renovation or Reengineered Facilities1.9 Facilities Planning and Design Constraints1.10 Summary and Conclusion1.11 Exercises References Factory Layout and Material Handling Project 2.1 Introduction2.2 Project Overview Computerized Format Files Basic Documents Project Report2.3 Section I: Product Analysis Production Drawings Parts List and Identification System Assembly Flowchart2.4 Section II: Parts Manufacturing Route Sheets Machine Requirements and Costs Machine Requirements Machine Costs Material Requirements Machine Drawings2.5 Section III: Layouts Planning Layout Planning Charts Material handling Requirements and Costs2.6 Section IV: Personnel Planning Personnel Requirements and Costs Unit Costs2.7 Section V: Office Layout2.8 Section VI: Recommended Plant Layout Product Design and Process Planning 3.1 Market Research Types of Market Research Qualitative Forecasting Methods Quantitative Forecasting Methods3.2 Product Design Product Design Process Bill of Materials or part List Component Part Drawing Assembly Drawing3.3 Product Design Concurrent Engineering Quality Function DeploymentValue Analysis 3.4 Factory Design Project: Section I. Product Design What Product? What Parts Compose the Product?Guidelines Report Organization 3.5 Process Planning Process Planning Procedure Selection of Manufacturing Sequencing of Manufacturing Processes 3.6 Types of Process Planning Manual Process Planning Variant Process Planning Generative Process Planning Generative Process Planning (GPP) Semigenerative Process Planning Computer-Aided Manufacturing3.7 Schedule3.8 Factory Design Project: Section II. Process Design Guidelines Organization of Report3.9 Summary3.10 ExercisesReferences Layout Planning Procedures 4.1 Introduction4.2 Systematic Layout Planning4.3 From-To Program4.4 Production Flow Analysis Overview of Conceptual ApproachIntegration of SLP and PFA4.5 Flow Planning4.6 Layout Planning Chart4.7 Space Requirements4.8 Facility Layout (FLAP) Description and Illustration of Procedure Facilities layout Program (FLAP): User Instructions4.9 Summary4.10 Exercises References Location Models in facility Planning 5.1 Single-Facility Location Model Minisum Location Problem with Rectilinear Distances Extension to Rectangular Areas Minimax Location Model for Single Facility Minimax Location Problem for Rectilinear Distances5.2 Location-Allocation Problem Mathematical Model Solution Procedure5.3 Quadratic Assignment Problem (QAP)5.4 Heuristic Methods for Solving the QAP Incremental Cost after adding a new facility Pairwise Interchange Heuristic Construction Procedure Heuristic Improvement Procedure5.5 Exercises Computerized Layout Procedures 6.1 Introduction6.2 Scope and Definitions6.3 Facility Layout Software Issues6.4 Exact QAP and GTLN Optimization Procedures Exact Graph-Theoretic Procedures 6.5 Heuristic Procedures Improvement Procedures Improvement Algorithms Construction Procedures 6.6 Quadratic Set Packing ModelsProblem Statement and Objective Branch-and-Bound AlgorithmManufacturing Layout Solution Factory Project Examples6.7 STEP Algorithm Stochastic Examples Algorithm Sampling test and Pairwise Exchange Procedure The Concept of the Sampling Test Computational Results Factory Project Example6.8 Summary6.9 Exercises References Material Handling Principles, Equipment, and System Design 7.1 Introduction Motivation 7.2 Scope and Definitions 7.3 Principles of Material Handling (PAS1 S 2AGES) Unit Load Principle S27.4 Designing Material Handling Systems (MHS)7.5 Material Handling Equipment Conveyors Monorails, Hoists, and Cranes Industrial Trucks7.6 MHS Decision-Support Tool Architecture of the Application The Knowledge Base Development of Knowledge Base Developing the Decision-Support System Advantages of DSS Two-Step Approach Limitations of Existing Expert Systems Decision-Support System for Material Handling Equipment Selection Flow of the Application DSS Stage II for Cranes Final Synthesis 7.7 Factory Design Project: Section III. Layout Planning and Material Handling Layout Planning Chart Material Handling Requirements Material Handling Costs Proposed Layout Sample Calculations Report Organization Initial Layout Material handling Requirements and Costs7.8 Summary and Conclusion7.9 Exercises References Material Handling Systems Analysis 8.1 Introduction Motivation 8.2 Integration of Layout and Material Handling System Fundamental Integration Principle Case Study Addenda to Section III of Project8.3 Open Network System Design Tool: GQnet GQnet Basic Assumptions GQnet Algorithm GQnet Computational Results8.4 Closed-Loop Conveyor Systems Overview Deterministic Conveyor Model Conveyor Example Stochastic Analytical Approaches Algorithms Computer Experiments8.5 Simulation Models Introduction Cellular Methodology Simulation Section Outline Background of Case Study Individual Cell Simulation Model Cell Network Study8.6 Warehouse Simulation Motivation Background Problem DescriptionLayout of factory 8.7 Summary and Conclusions8.8 Exercises References Storage and Warehouse Systems 9.1 Introduction 9.2 Receiving and shipping Receiving and Putaway Operations Processing Customer Orders Order Picking Packing and Shipping Cross Docking9.3 Dedicated and Random Storage Dedicated Storage Random Storage9.4 Models for Determining Storage Capacity Service-Level Approach Cost-Based Approach9.5 Storage-Capacity Determination Randomized Storage Policy9.6 Dock Planning and Design Dock Location Types of Docks Dock Design Dock Levelers Dock Safety 9.7 Warehouse Systems Design Storage Equipment Carousels Rack Storage Systems9.8 Automated Storage and Retrieval Systems (AS/RS)9.9 Exercises References Site-Planning Design 10.1 Introduction Motivation Example Sitting Problem10.2 Site-Planning Methodology Objective /Attribute Hierarchy Basic Assumptions First Assumption Second Assumption Third Assumption Fourth Assumption Performance Functions10.3 Site-Selection Criteria Physical Criteria Cultural Criteria Functional Criteria 10.4 Manufacturing Site-Planning Examples Objective Function (Distance or Time) Site-Planning Example 10.5 Factory Project Case Study Soils Slopes Views Evaluation Site Drainage Final Summary Evaluation Factory Project Site- Planning Example10.6 Summary and Conclusions 10.7 Exercises References Office and Personnel Layout Planning 11.1 Introduction History Outline of Chapter11.2 Office Spatial Organization Problem General Functions of Office11.3 Office Space GuidelinesAncillary Space GuidelinesMiscellaneous Areas of Offices 11.4 Personnel Requirements and Office Arrangements Personnel Requirements Types of Office Arrangements Example Office layout 11.5 Utility Company office case StudyAlternative1Alternative 2Alternative 3Alternative 4Analysis and conclusions11.6 Factory Design Project: Section IV. Personnel Requirements and Calculation of Product Total Unit CostConceptual Overview Organization of Report Positions and Job Descriptions11.7 Factory Design Project: Section V. Office Layout Planning Overall Conceptual Approach Report Organization Selected Office Layout 11.8 Summary and conclusions11.9 Exercises References Final Synthesis 12.1 IntroductionOverview of ChapterProfessions Involved in Facilities PlanningLeased Facility for Project 12.2 New vs. Existing Buildings12.3 Structural Engineering Roofs and Floors Walls and Columns Building-Code Considerations12.4 Heating, Ventilating and Air-Conditioning (HVAC) Electrical/Lighting Plumbing Vertical Transportation12.5 Functional Adaptation of Existing Buildings Adaptability Flexibility12.6 Building Economics Structural System Architectural Mechanical Systems Administrative Costs Cultural 12.7 Factory Design Project: Section VI. Recommended Plant Layout Factory Report Organization Plant layout Summary Sheet Checklist for Final Report Breakeven-Point Analysis Factory Project Presentation Guidelines References Appendix: Renovation vs. New Construction Planning Issues Structural Mechanical/Electrical Functional Financial Cultural