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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 Process 1.2 Hierarchical Cycle of Facilities Planning 1.3 Objectives of Facilities Planning Issue-Based Information Systems Site-Planning IBIS Example Decision-Support (DSS) Computer Programs 1.4 Mathematical Models in Facility Planning 1.5 Manufacturing Systems Concepts 1.6 Types of Basic Manufacturing Layouts Fixed-Position Layout Product Layout Process Process Layout Process Cellular Layout Process 1.7 Service Systems 1.8 Renovation or Reengineered Facilities 1.9 Facilities Planning and Design Constraints 1.10 Summary and Conclusion 1.11 Exercises References Factory Layout and Material Handling Project 2.1 Introduction 2.2 Project Overview Computerized Format Files Basic Documents Project Report 2.3 Section I: Product Analysis Production Drawings Parts List and Identification System Assembly Flowchart 2.4 Section II: Parts Manufacturing Route Sheets Machine Requirements and Costs Machine Requirements Machine Costs Material Requirements Machine Drawings 2.5 Section III: Layouts Planning Layout Planning Charts Material handling Requirements and Costs 2.6 Section IV: Personnel Planning Personnel Requirements and Costs Unit Costs 2.7 Section V: Office Layout 2.8 Section VI: Recommended Plant Layout Product Design and Process Planning 3.1 Market Research Types of Market Research Qualitative Forecasting Methods Quantitative Forecasting Methods 3.2 Product Design Product Design Process Bill of Materials or part List Component Part Drawing Assembly Drawing 3.3 Product Design Concurrent Engineering Quality Function Deployment Value 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 Manufacturing 3.7 Schedule 3.8 Factory Design Project: Section II. Process Design Guidelines Organization of Report 3.9 Summary 3.10 Exercises References Layout Planning Procedures 4.1 Introduction 4.2 Systematic Layout Planning 4.3 From-To Program 4.4 Production Flow Analysis Overview of Conceptual Approach Integration of SLP and PFA 4.5 Flow Planning 4.6 Layout Planning Chart 4.7 Space Requirements 4.8 Facility Layout (FLAP) Description and Illustration of Procedure Facilities layout Program (FLAP): User Instructions 4.9 Summary 4.10 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 Distances 5.2 Location-Allocation Problem Mathematical Model Solution Procedure 5.3 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 Procedure 5.5 Exercises Computerized Layout Procedures 6.1 Introduction 6.2 Scope and Definitions 6.3 Facility Layout Software Issues 6.4 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 Models Problem Statement and Objective Branch-and-Bound Algorithm Manufacturing Layout Solution Factory Project Examples 6.7 STEP Algorithm Stochastic Examples Algorithm Sampling test and Pairwise Exchange Procedure The Concept of the Sampling Test Computational Results Factory Project Example 6.8 Summary 6.9 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 S2 7.4 Designing Material Handling Systems (MHS) 7.5 Material Handling Equipment Conveyors Monorails, Hoists, and Cranes Industrial Trucks 7.6 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 Costs 7.8 Summary and Conclusion 7.9 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 Project 8.3 Open Network System Design Tool: GQnet GQnet Basic Assumptions GQnet Algorithm GQnet Computational Results 8.4 Closed-Loop Conveyor Systems Overview Deterministic Conveyor Model Conveyor Example Stochastic Analytical Approaches Algorithms Computer Experiments 8.5 Simulation Models Introduction Cellular Methodology Simulation Section Outline Background of Case Study Individual Cell Simulation Model Cell Network Study 8.6 Warehouse Simulation Motivation Background Problem Description Layout of factory 8.7 Summary and Conclusions 8.8 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 Docking 9.3 Dedicated and Random Storage Dedicated Storage Random Storage 9.4 Models for Determining Storage Capacity Service-Level Approach Cost-Based Approach 9.5 Storage-Capacity Determination Randomized Storage Policy 9.6 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 Systems 9.8 Automated Storage and Retrieval Systems (AS/RS) 9.9 Exercises References Site-Planning Design 10.1 Introduction Motivation Example Sitting Problem 10.2 Site-Planning Methodology Objective /Attribute Hierarchy Basic Assumptions First Assumption Second Assumption Third Assumption Fourth Assumption Performance Functions 10.3 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 Example 10.6 Summary and Conclusions 10.7 Exercises References Office and Personnel Layout Planning 11.1 Introduction History Outline of Chapter 11.2 Office Spatial Organization Problem General Functions of Office 11.3 Office Space Guidelines Ancillary Space Guidelines Miscellaneous 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 Study Alternative1 Alternative 2 Alternative 3 Alternative 4 Analysis and conclusions 11.6 Factory Design Project: Section IV. Personnel Requirements and Calculation of Product Total Unit Cost Conceptual Overview Organization of Report Positions and Job Descriptions 11.7 Factory Design Project: Section V. Office Layout Planning Overall Conceptual Approach Report Organization Selected Office Layout 11.8 Summary and conclusions 11.9 Exercises References Final Synthesis 12.1 Introduction Overview of Chapter Professions Involved in Facilities Planning Leased Facility for Project 12.2 New vs. Existing Buildings 12.3 Structural Engineering Roofs and Floors Walls and Columns Building-Code Considerations 12.4 Heating, Ventilating and Air-Conditioning (HVAC) Electrical/Lighting Plumbing Vertical Transportation 12.5 Functional Adaptation of Existing Buildings Adaptability Flexibility 12.6 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
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- ID: 9781292042893
Pearson New International Edition
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