Manufacturing facilities design and material handling

✍ Scribed by Stephens, Matthew P;Meyers, Fred E

• Publisher: Prentice Hall; Pearson Education
• Year: 2009;2010
• Tongue: English
• Leaves: 509
• Edition: 4th ed
• Category: Library

✦ Synopsis

The authors take a practical, hands-on, project-oriented approach to exploring the techniques & procedures for developing an efficient facility layout. The text also introduces state-of-the-art tools, including computer simulation.

✦ Table of Contents

Cover......Page 1
CONTENTS......Page 14
The Importance of Manufacturing Facilities Design and Material Handling......Page 24
Lean Thinking and Lean Manufacturing......Page 27
The Goals of Manufacturing Facilities Design and Material Handling......Page 29
The Manufacturing Facilities Design Procedure......Page 35
Types and Sources of Manufacturing Facilities Design Projects......Page 37
Computers and Simulation in Manufacturing Facilities Design......Page 38
ISO 9000 and Facilities Planning......Page 39
Glossary of Some Major Terms and Concepts in Facilities Planning......Page 41
Questions......Page 44
A Project in the Making......Page 45
Objectives......Page 49
The Marketing Department......Page 50
Determining Takt Time or Plant Rate......Page 51
Calculating Scrap and Rework Rates......Page 52
The Product Design Department......Page 54
The Indented Bill of Material......Page 59
Lean Thinking and Muda as Part of Management Policy......Page 63
Startup Schedule......Page 64
Make or Buy Decisions......Page 65
Feasibility Studies......Page 66
Conclusion......Page 67
Questions......Page 68
A Project in the Making......Page 69
Objectives......Page 74
What is a Time Standard?......Page 75
The Importance and Uses of Time Study......Page 76
1. How Many Machines Do We Need?......Page 78
2. How Many People Should We Hire?......Page 79
3. How Much Will Our Product Cost?......Page 82
4. When Should We Start a Job, and How Much Work Can We Handle with the Equipment and People We Have? Or, How Do We Schedule and Load Machines, Work Centers, Departments, and Plants?......Page 83
5. How Do We Determine the Assembly Line Balance and the Conveyor Belt Speed, Load the Work Cells with the Correct Amount of Work, and Balance the Work Cells?......Page 84
6. How Do We Measure Productivity?......Page 85
7. How Can We Pay Our People for Outstanding Performance?......Page 86
8. How Can We Select the Best Method or Evaluate Cost Reduction Ideas?......Page 87
Techniques of Time Study......Page 89
Stopwatch Time Study......Page 90
Time Study Procedure and the Step-by-Step Form......Page 94
Rating, Leveling, and Normalizing......Page 103
Types of Allowances......Page 105
Methods of Applying Allowances......Page 109
Work Sampling......Page 112
Standard Data......Page 113
Expert Opinion Time Standards and Historical Data......Page 114
Time Standards for Manufacturing Facilities Design......Page 115
Questions......Page 116
A Project in the Making......Page 118
Objectives......Page 119
Route Sheets......Page 120
The Number of Machines Needed......Page 124
Work Cell Load Chart......Page 125
Step-by-Step Procedure for Preparing a Work Cell Load Chart......Page 127
Plant Rate and Conveyor Speed......Page 130
Paint Conveyor Speed......Page 132
Assembly Line Balancing......Page 134
Step-by-Step Procedure for Completing the Assembly Line Balancing Form......Page 138
Calculating the Efficiency of the Assembly Line......Page 141
Use of Computer Simulation......Page 142
Layout Orientation......Page 145
Questions......Page 146
A Project in the Making......Page 148
Objectives......Page 158
String Diagram......Page 162
Multicolumn Process Chart......Page 164
From-To Chart......Page 166
Process Chart......Page 168
Step-by-Step Description for the Process Chart......Page 170
Flow Diagrams......Page 174
Step-by-Step Procedure for Developing a Flow Diagram......Page 177
Step-by-Step Procedure for Preparing an Operations Chart......Page 178
Flow Process Chart......Page 180
Computer-Aided Flow Design and Analysis......Page 182
Questions......Page 187
A Project in the Making......Page 188
Objectives......Page 198
Activity Relationship Diagram......Page 199
Determining the Relationship Code......Page 201
Dimensionless Block Diagram......Page 203
Computer-Generated Activity Relationship Chart......Page 206
Questions......Page 209
A Project in the Making......Page 211
Workstation Design......Page 218
Ergonomics and the Principles of Motion Economy......Page 220
Principle 1: Hand Motions......Page 221
Principle 2: Basic Motion Types......Page 225
Principle 3: Location of Parts and Tools......Page 226
Principle 4: Freeing the Hands from as Much Work as Possible......Page 228
Principle 6: Operator Safety and Health Considerations......Page 229
Space Determination......Page 230
Questions......Page 233
Receiving and Shipping......Page 234
The Trucking Industry’s Effect on Receiving and Shipping......Page 235
Functions of a Receiving Department......Page 236
Facilities Required for a Receiving Department......Page 238
Functions of a Shipping Department......Page 240
Storage......Page 246
Maximizing the Use of the Cubic Space......Page 248
Providing Immediate Access to Everything (Selectivity)......Page 250
Warehousing......Page 259
Warehouse Design Criteria......Page 260
Functions of a Warehouse......Page 262
Procedure for Sales Analysis of ABC Inventory......Page 263
ABC Inventory Layout of a Hand Tool Manufacturing Company’s Warehouse......Page 264
Warehouse Space Determination......Page 267
Conclusion......Page 269
Maintenance and Tool Room......Page 271
Questions......Page 272
Objectives......Page 274
Parking Lots......Page 275
Employee Entrance......Page 276
Locker Rooms......Page 278
Restrooms and Toilets......Page 279
Cafeterias or Lunchrooms......Page 280
Recreational Facilities......Page 284
Aisles......Page 285
Medical Facilities......Page 286
Miscellaneous Employee Services......Page 287
Questions......Page 289
A Project in the Making......Page 290
Objectives......Page 297
Cost Justification......Page 298
Sample Material Handling Cost Problem......Page 299
Ten Principles of Material Handling......Page 300
Planning Principle......Page 305
Systems Principle......Page 307
Space Utilization Principle......Page 308
Unit Load Principle......Page 309
Standardization Principle......Page 310
The Material Handling Problem-Solving Procedure......Page 311
Questions......Page 316
Objectives......Page 317
Receiving and Shipping Docks......Page 318
Moving Equipment......Page 322
Telescopic Conveyor......Page 327
Weight Scale......Page 330
Storage Units......Page 331
Stores Mobile Equipment......Page 334
Systems Required for the Stores Department......Page 338
Shop Containers......Page 340
Tubs and Baskets......Page 341
Manipulators and Lifting Devices......Page 345
Mobile Fabrication Equipment......Page 352
Assembly and Paint......Page 359
Powered Roller Conveyors......Page 360
Slat Conveyors......Page 361
Tow Conveyors......Page 362
Overhead Trolley Conveyors......Page 363
Packout......Page 365
Automatic Taping, Gluing, and Stapling......Page 366
Banding......Page 368
Clamp Trucks......Page 373
Vertical Warehouse and Picking Cars......Page 377
Shipping Containers......Page 379
Bulk Material Handling......Page 382
Bulk Material Conveyors......Page 383
Cross-Docking and Flow-Through......Page 385
Questions......Page 391
A Project in the Making......Page 392
Objectives......Page 398
Goals of Office Layout Design......Page 399
Open Office Space......Page 400
The Modern Office......Page 403
Special Requirements and Considerations......Page 406
Techniques of Office Layout......Page 410
Organizational Chart......Page 411
Communications Force Diagram......Page 412
Activity Relationship Diagram......Page 415
Activity Worksheet......Page 416
Dimensionless Block Diagram......Page 417
Detailed Master Layout......Page 420
Questions......Page 422
Space Requirements Planning......Page 423
Overhead or Clear Space Areas......Page 425
Building Size Determination......Page 426
Dimensionless Block Diagram......Page 427
Area Allocation Procedure......Page 428
Office Area Allocation......Page 429
Questions......Page 433
Plot Plan......Page 434
Plant Layout Methods......Page 437
Master Plan......Page 438
Computer-Aided Design (CAD) Technique......Page 443
Advanced Computer Systems......Page 444
Plant Layout Procedure—Toolbox Plant......Page 447
Office Layout for the Toolbox Plant......Page 450
Evaluation......Page 452
Questions......Page 457
A Project in the Making......Page 458
Introduction......Page 464
Defining Computer Simulation......Page 465
Advantages and Disadvantages of Simulation......Page 466
Simulation in Facilities Planning......Page 467
How Simulation Works......Page 468
Computer-Aided Layout Design......Page 470
Computer-Assisted Layout Performance Analysis......Page 472
Case Studies......Page 477
Simulation in Waste Handling......Page 478
Questions......Page 479
The Project Report......Page 480
The Presentation......Page 482
Approval......Page 483
Installation......Page 484
Debugging and Follow-Up......Page 485
Conclusion......Page 486
ANSWERS......Page 488
B......Page 500
C......Page 501
E......Page 502
F......Page 503
M......Page 504
O......Page 505
P......Page 506
S......Page 507
V......Page 508
X......Page 509

✦ Subjects

Science;Engineering