Facilities Planning and Design

✍ Scribed by Alberto Garcia-Diaz, J. MacGregor Smith(Deceased)

• Publisher: Springer
• Year: 2024
• Tongue: English
• Leaves: 560
• Edition: 2
• Category: Library

✦ Synopsis

​This updated, expanded, second edition includes new software methodologies and algorithms providing students with a more comprehensive knowledge base in addition to facilitating and making the project component of the textbook more efficient and effective. It further increases emphasis on manufacturing. Retaining its class-tested pedagogy, the book is concerned with the principles of facilities planning and their application to service, business, and product manufacturing operations. Equipping undergraduate students with the fundamentals of facilities planning, design, location and material handling, especially as they apply to industrial manufacturing facilities, the book is ideal for a range of university settings offering courses on facilities planning.

✦ Table of Contents

Preface
Textbook Website
Contents
Chapter 1: Fundamental Principles of Facilities Planning and Design
1.1 Introduction
1.1.1 What Is Design?
1.1.2 Characteristics of Design Problems
1.1.3 Design Program
1.1.4 Design Process
1.2 Hierarchical Cycle of Facilities Planning
1.3 Objectives of Facilities Planning
1.3.1 Issue-Based Information Systems (IBIS)
1.3.2 Site-Planning IBIS Example
1.3.3 Decision-Support Computer Programs
1.4 Mathematical Models in Facility Planning
1.5 Manufacturing Systems Concepts
1.6 Types of Basic Manufacturing Layouts
1.6.1 Fixed-Position Layout
1.6.2 Product Layout
1.6.3 Process Layout
1.6.4 Cellular Layout
1.7 Service Systems
1.8 Renovated or Reengineered Facilities
1.9 Facilities Planning and Design Constraints
1.10 Summary and Conclusion
1.11 Exercises
References
Chapter 2: Factory Layout and Material Handling Project
2.1 Introduction
2.2 Project Overview
2.2.1 Computerized Format Files
2.2.2 Basic Documents
2.2.3 Project Report
2.3 Section I: Product Analysis
2.3.1 Production Drawings
2.3.2 Parts List and Identification System
2.3.3 Assembly Flowchart
2.4 Section II: Parts Manufacturing
2.4.1 Route Sheets
2.4.2 Machine Requirements and Costs
2.4.3 Machine Requirements
2.4.4 Machine Costs
2.4.5 Material Requirements
2.4.6 Machine Drawings
2.5 Section III: Layout Planning
2.5.1 Layout Planning Charts
2.5.2 Material Handling Requirements and Costs
2.6 Section IV: Personnel Planning
2.6.1 Personnel Requirements and Costs
2.6.2 Unit Costs
2.7 Section V: Office Layout
2.8 Section VI: Recommended Plant Layout
Chapter 3: Product Design and Process Planning
3.1 Market Research
3.1.1 Types of Market Research
3.1.2 Qualitative Forecasting Methods
3.1.3 Quantitative Forecasting Methods
3.2 Product Design
3.2.1 Product Design Process
3.2.2 Bill of Materials or Part List
3.2.3 Component Part Drawings
3.2.4 Assembly Drawing
3.3 Product Design Tools
3.3.1 Concurrent Engineering
3.3.2 Quality Function Deployment
3.3.3 Value Analysis
3.4 Factory Design Project: Section I. Product Design
3.4.1 What Product?
3.4.2 What Parts Compose the Product?
3.4.3 Guidelines
3.4.4 Report Organization
3.5 Process Planning
3.5.1 Process Planning Procedure
3.5.2 Selection of Manufacturing Processes
3.5.3 Sequencing of Manufacturing Processes
3.6 Types of Process Planning
3.6.1 Manual Process Planning
3.6.2 Variant Process Planning
3.6.3 Generative Process Planning (GPP)
3.6.4 Semigenerative Process Planning
3.6.5 Computer Aided Manufacturing
3.7 Schedule Design
3.8 Factory Design Project: Section II. Process Design
3.8.1 Guidelines
3.8.2 Organization of Report
3.9 Summary
3.10 Exercises
References
Chapter 4: Layout Planning Procedures
4.1 Introduction
4.2 Systematic Layout Planning
4.3 From-To Chart Program
4.3.1 From-To Chart for Machines Without Defective Item Probabilities
4.3.2 From-To Chart for Machines with Defective Item Probabilities
4.4 Production Flow Analysis
4.4.1 Overview of Conceptual Approach
4.4.2 Integration of SLP and PFA
4.5 Flow Planning
4.6 Layout Planning Chart
4.7 Space Requirements
4.8 A Closeness Relationship Procedure for Layout Planning
4.8.1 Description of Procedure
4.8.2 Illustration of Procedure
4.9 Computerized Layout Procedures for Factory Layout Project
4.10 Facilities Layout Program (FLAP)
4.10.1 Overview and Illustration of Program FLAP
4.11 Computerized Relative Allocation of Facilities Technique (CRAFT)
4.11.1 Overview and Illustration of Program CRAFT
4.12 Multi-Attribute Facility Layout and Design Program (MAFLAD)
4.12.1 Overview of Program MAFLAD
4.12.2 Branch-and-Bound Algorithm
4.12.3 An Illustration of Program MAFLAD
4.12.4 Factory Project GMAFLAD Example
4.13 Summary and Recommendations
4.14 Exercises
References
Chapter 5: Facility Location Models
5.1 Introduction
5.1.1 Facility Location Models
5.1.2 Siting Problem
5.2 Site Planning Design: Concepts and Example
5.2.1 Site Description
5.3 Single-Facility Location Model
5.3.1 Minisum Location Model with Rectilinear Distances
5.3.1.1 Cumulative Weight Diagram
5.3.1.2 Contours for Minisum Model
5.3.2 Extension to Rectangular Areas
5.3.3 Minimax Location Model for Single-Facility
5.3.4 Minimax Location Model for Rectilinear Distances
5.3.4.1 Contours for Minimax Model
5.4 Location-Allocation Problem
5.4.1 Mathematical Model
5.4.2 Solution Procedure
5.5 Quadratic Assignment Problem
5.6 Heuristic Methods for Solving the QAP
5.6.1 Incremental Cost After Adding a New Facility
5.6.2 Pairwise Interchange
5.6.3 Heuristic Construction Procedure
5.6.4 Heuristic Improvement Procedure
5.7 Exercises
References
Chapter 6: 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
6.4.1 Exact Graph-Theoretic Procedures
6.5 Heuristic Procedures
6.5.1 Improvement Procedures
6.5.2 Construction Procedures
6.5.3 Graph-Theoretic Heuristics
6.6 Software Integration
6.6.1 Departmental Area Requirements
6.6.2 From-To Chart
6.6.3 Initial Solutions
6.6.4 CRAFT Final Layout
6.7 STEP Algorithm
6.7.1 Network Representation of the Facility
6.7.2 Assumptions, Notation, and Special Terminology
6.7.3 Facility Layout with an M/G/ System
6.7.4 Stochastic Example
6.7.5 Algorithm
6.7.6 The Concept of Sampling Test
6.7.7 Computational Results
6.7.8 A Factory Project Example
6.8 Summary
6.9 Exercises
References
Chapter 7: Material Handling Principles, Equipment, and System Design
7.1 Introduction
7.2 Scope and Definitions
7.3 Principles of Material Handling
7.3.1 Unit Load Principle
7.4 Designing Material Handling Systems
7.5 Material Handling Equipment
7.5.1 Conveyors
7.5.1.1 Conveyor Control
7.5.1.2 Accessories
7.5.2 Monorails, Hoists, and Cranes
7.5.3 Industrial Trucks
7.6 Decision Support System for Material Handling Equipment Selection
7.6.1 Architecture of the Application
7.6.2 Developing the Knowledge Base
7.6.3 Developing the Decision-Support System
7.6.4 Developing Inference Chains
7.6.5 Advantages of DSS
7.6.6 Two-Step Approach
7.6.7 Limitations of Existing Expert Systems
7.7 DSS-MHE Program
7.7.1 Flow of the Application
7.7.2 Sample Run of DSS-MHE-UTK.EXE Program
7.7.3 Final Synthesis
7.8 Material Handling Requirements and Costs
7.9 Factory Design Project: Section III. Layout Planning and Material Handling
7.9.1 Layout Planning Chart
7.9.2 Material Handling Requirements
7.9.3 Material Handling Costs
7.9.4 Guidelines for Proposed Initial Layout
7.9.5 Sample Calculations
7.9.6 Report Organization
7.10 Summary and Conclusions
7.11 Exercises
References
Chapter 8: Material Handling Systems Analysis
8.1 Introduction
8.1.1 Motivation
8.1.2 Outline of Chapter
8.2 Integration of Layout and Material Handling System
8.2.1 Fundamental Integration Principles
8.2.2 Case Study
8.2.3 Addenda to Section III of Project
8.3 Open Network System Design Tool
8.3.1 GQnet Basic Assumptions
8.3.2 GQnet Algorithm
8.3.3 GQnet Computational Results
8.3.3.1 Medical Clinic Example
8.3.3.2 Manufacturing Facility Example
8.4 Closed-Loop Conveyor Systems
8.4.1 Deterministic Conveyor Model
8.4.1.1 Muth´s Basic Results
8.4.1.2 Carrier Analysis
8.4.1.3 Procedure for Finding the Capacity of the Carriers
8.4.1.4 Conveyor Example
8.4.2 Conveyor Analysis Program
8.4.3 Stochastic Analytical Approaches
8.4.3.1 Algorithmic Decomposition Procedure
8.4.3.2 Computer Experiments
8.5 Simulation Models
8.5.1 Cellular Methodology
8.5.2 Simulation Section Outline
8.5.3 Background of Case Study
8.5.4 Individual Cell Simulation Model
8.5.5 Cell Network Study
8.6 Warehouse Simulation
8.6.1 Motivation
8.6.2 Background
8.6.3 Problem Description
8.6.4 Factory Layout
8.7 Summary and Conclusions
8.8 Exercises
References
Chapter 9: Storage and Warehouse Systems
9.1 Introduction
9.2 Receiving and Shipping
9.2.1 Receiving and Putaway Operations
9.2.2 Processing Customer Orders
9.2.3 Order Picking
9.2.4 Packing and Shipping
9.2.5 Cross Docking
9.3 Dedicated and Random Storage
9.3.1 Dedicated Storage
9.3.2 Random Storage
9.4 Models for Determining Storage Capacity
9.4.1 Service-Level Approach
9.4.2 Cost-Based Approach
9.5 Storage-Capacity Determination
9.5.1 Randomized Storage Policy
9.5.2 Dedicated Storage Policy
9.6 Dock Planning and Design
9.6.1 Dock Location
9.6.2 Types of Docks
9.6.3 Dock Design
9.6.4 Dock Levelers
9.6.5 Dock Safety
9.7 Warehouse Systems Design
9.7.1 Storage Equipment
9.7.2 Carousels
9.7.3 Rack Storage Systems
9.8 Automated Storage and Retrieval Systems (AS/RS)
9.9 Exercises
References
Chapter 10: Site-Planning Design
10.1 Introduction
10.1.1 Motivation
10.1.2 Siting Problem Example
10.2 Site-Planning Methodology
10.2.1 Objective/Attribute Hierarchy
10.2.2 First Assumption
10.2.3 Second Assumption
10.2.4 Third Assumption
10.2.5 Fourth Assumption
10.2.6 Performance Functions
10.3 Site-Selection Criteria
10.3.1 Physical Criteria
10.3.1.1 Geology
10.3.1.2 Hydrology
10.3.1.3 Climate
10.3.1.4 Topography
10.3.1.5 Ecology
10.3.2 Cultural Criteria
10.3.2.1 Legal/Political
10.3.2.2 Financial
10.3.2.3 Historical
10.3.3 Functional Criteria
10.3.3.1 Image
10.3.3.2 Land Utilization
10.3.4 Site Accessibility
10.3.4.1 Adaptability
10.4 Manufacturing Site-Planning Example
10.5 Factory Project Case Study
10.5.1 Soils
10.5.2 Slopes
10.5.3 Views Evaluation
10.5.4 Site Accessibility
10.5.5 Noise Evaluation
10.5.6 Site-Development Costs
10.5.7 Site Drainage
10.5.8 Summary Evaluation
10.6 Summary and Conclusions
10.7 Exercises
Appendix 10.1 Site-Planning
Geology Planning Issues
Hydrology Planning Issues
Climactic Planning Issues
Topographic Planning Issues
Ecological Planning Issues
Cultural Planning Issues
Financial Planning Issues
Image Planning Issues
Land Utilization Planning Issues
Administrative Planning Issues
Accessibility Planning Issues
Adaptability Planning Issues
Site Utility Planning Issues
References
Chapter 11: Office Layout and Personnel Planning
11.1 Introduction
11.1.1 History of Offices
11.1.2 Outline of Chapter
11.2 Office Spatial Organization Problem
11.2.1 General Functions of Offices
11.2.2 Organization Chart
11.3 Office Space Guidelines
11.3.1 Ancillary Space Guidelines
11.3.2 Miscellaneous Areas or Offices
11.4 Personnel Requirements and Office Arrangements
11.4.1 Personnel Requirements
11.4.2 Types of Office Arrangements
11.4.3 Office Layout Example
11.5 Utility Company Office Case Study
11.5.1 Alternative 1
11.5.2 Alternative 2
11.5.3 Alternative 3
11.5.4 Alternative 4
11.5.5 Analysis and Conclusions
11.6 Factory Design Project: Section IV. Personnel Requirements and Calculation of Product Unit Cost
11.6.1 Conceptual Overview
11.6.2 Organization of Report
11.6.3 Positions and Job Descriptions
11.7 Unit Cost Calculation Template
11.8 Factory Design Project: Section V. Office Layout Planning
11.8.1 Conceptual Approach
11.8.2 Report Organization
11.8.3 Selected Office Layout
11.9 Summary and Conclusions
11.10 Exercises
References
Chapter 12: Final Synthesis
12.1 Introduction
12.1.1 Overview of Chapter
12.1.2 Professions Involved in Facilities Planning
12.1.3 Leased Facility for Project
12.2 New Versus Existing Buildings
12.3 Structural Engineering
12.3.1 Roofs and Floors
12.3.2 Walls and Columns
12.3.3 Building-Code Considerations
12.4 Heating, Ventilating, and Air-Conditioning
12.4.1 Electrical/Lighting
12.4.2 Plumbing
12.4.3 Vertical Transportation
12.5 Functional Adaptation of Existing Buildings
12.5.1 Adaptability
12.5.2 Flexibility
12.6 Building Economics
12.6.1 Structural System
12.6.2 Architectural Costs
12.6.3 Mechanical Systems
12.6.4 Administrative Costs
12.6.5 Cultural
12.6.6 Factory Renovation Project
12.7 Factory Design Project: Section VI. Recommended Layout
12.7.1 Factory Report Organization
12.7.2 Plant Layout Summary Sheet
12.7.3 Checklist for Final Report
12.7.4 Final Layout
12.7.4.1 Flow Considerations
12.7.4.2 Space Considerations
12.7.4.3 Activity Relationships
12.7.5 Break-Even Point Analysis
12.7.6 Factory Design Project Presentation Guidelines
Appendix 12.1 Renovation Versus New Construction Planning Issues
Structural
Mechanical/Electrical
Functional
Financial
Cultural
References
Appendix: Decision Support Methodology (DSM)
Introduction
Modules
Material Selection and Cost Determination
Machine Selection and Cost Determination
Material Handling Equipment Selection and Cost Determination
Labor Cost Determination
General Question Form
Part Details Form
Machine Form
Personnel Form
Part Cost Results Form
Index