| |
| |
Fundamental Principles of Facilities Planning and Design | |
| |
| |
| |
Introduction | |
| |
| |
What is Design | |
| |
| |
Characteristics of Design Problems | |
| |
| |
Design Program | |
| |
| |
Design Process | |
| |
| |
| |
Hierarchical Cycle of Facilities Planning | |
| |
| |
| |
Objectives of Facilities Planning | |
| |
| |
Issue-Based Information Systems | |
| |
| |
Site-Planning IBIS Example | |
| |
| |
Decision-Support (DSS) Computer Programs | |
| |
| |
| |
Mathematical Models in Facility Planning | |
| |
| |
| |
Manufacturing Systems Concepts | |
| |
| |
| |
Types of Basic Manufacturing Layouts | |
| |
| |
Fixed-Position Layout | |
| |
| |
Product Layout Process | |
| |
| |
Process Layout Process | |
| |
| |
Cellular Layout Process | |
| |
| |
| |
Service Systems | |
| |
| |
| |
Renovation or Reengineered Facilities | |
| |
| |
| |
Facilities Planning and Design Constraints | |
| |
| |
| |
Summary and Conclusion | |
| |
| |
| |
Exercises | |
| |
| |
References | |
| |
| |
Factory Layout and Material Handling Project | |
| |
| |
| |
Introduction | |
| |
| |
| |
Project Overview | |
| |
| |
Computerized Format Files | |
| |
| |
Basic Documents | |
| |
| |
Project Report | |
| |
| |
| |
Section I: Product Analysis | |
| |
| |
Production Drawings | |
| |
| |
Parts List and Identification System | |
| |
| |
Assembly Flowchart | |
| |
| |
| |
Section II: Parts Manufacturing | |
| |
| |
Route Sheets | |
| |
| |
Machine Requirements and Costs | |
| |
| |
Machine Requirements | |
| |
| |
Machine Costs | |
| |
| |
Material Requirements | |
| |
| |
Machine Drawings | |
| |
| |
| |
Section III: Layouts Planning | |
| |
| |
Layout Planning Charts | |
| |
| |
Material handling Requirements and Costs | |
| |
| |
| |
Section IV: Personnel Planning | |
| |
| |
Personnel Requirements and Costs | |
| |
| |
Unit Costs | |
| |
| |
| |
Section V: Office Layout | |
| |
| |
| |
Section VI: Recommended Plant Layout | |
| |
| |
Product Design and Process Planning | |
| |
| |
| |
Market Research | |
| |
| |
Types of Market Research | |
| |
| |
Qualitative Forecasting Methods | |
| |
| |
Quantitative Forecasting Methods | |
| |
| |
| |
Product Design | |
| |
| |
Product Design Process | |
| |
| |
Bill of Materials or part List | |
| |
| |
Component Part Drawing | |
| |
| |
Assembly Drawing | |
| |
| |
| |
Product Design | |
| |
| |
Concurrent Engineering | |
| |
| |
Quality Function Deployment | |
| |
| |
Value Analysis | |
| |
| |
| |
Factory Design Project: Section I. | |
| |
| |
Product Design | |
| |
| |
What Product? | |
| |
| |
What Parts Compose the Product? | |
| |
| |
Guidelines | |
| |
| |
Report Organization | |
| |
| |
| |
Process Planning | |
| |
| |
Process Planning Procedure | |
| |
| |
Selection of Manufacturing | |
| |
| |
Sequencing of Manufacturing Processes | |
| |
| |
| |
Types of Process Planning | |
| |
| |
Manual Process Planning | |
| |
| |
Variant Process Planning | |
| |
| |
Generative Process Planning | |
| |
| |
Generative Process Planning (GPP) | |
| |
| |
Semigenerative Process Planning | |
| |
| |
Computer-Aided Manufacturing | |
| |
| |
| |
Schedule | |
| |
| |
| |
Factory Design Project: Section II. Process Design | |
| |
| |
Guidelines | |
| |
| |
Organization of Report | |
| |
| |
| |
Summary | |
| |
| |
| |
Exercises | |
| |
| |
References | |
| |
| |
Layout Planning Procedures | |
| |
| |
| |
Introduction | |
| |
| |
| |
Systematic Layout Planning | |
| |
| |
| |
From-To Program | |
| |
| |
| |
Production Flow Analysis | |
| |
| |
Overview of Conceptual Approach | |
| |
| |
Integration of SLP and PFA | |
| |
| |
| |
Flow Planning | |
| |
| |
| |
Layout Planning Chart | |
| |
| |
| |
Space Requirements | |
| |
| |
| |
Facility Layout (FLAP) | |
| |
| |
Description and Illustration of Procedure | |
| |
| |
Facilities layout Program (FLAP): User Instructions | |
| |
| |
| |
Summary | |
| |
| |
| |
Exercises | |
| |
| |
References | |
| |
| |
Location Models in facility Planning | |
| |
| |
| |
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 | |
| |
| |
| |
Location-Allocation Problem | |
| |
| |
Mathematical Model | |
| |
| |
Solution Procedure | |
| |
| |
| |
uadratic Assignment Problem (QAP) | |
| |
| |
| |
Heuristic Methods for Solving the QAP | |
| |
| |
Incremental Cost after adding a new facility | |
| |
| |
Pairwise Interchange | |
| |
| |
Heuristic Construction Procedure | |
| |
| |
Heuristic Improvement Procedure | |
| |
| |
| |
Exercises | |
| |
| |
Computerized Layout Procedures | |
| |
| |
| |
Introduction | |
| |
| |
| |
Scope and Definitions | |
| |
| |
| |
Facility Layout Software Issues | |
| |
| |
| |
Exact QAP and GTLN Optimization Procedures | |
| |
| |
Exact Graph-Theoretic Procedures | |
| |
| |
| |
Heuristic Procedures | |
| |
| |
Improvement Procedures | |
| |
| |
Improvement Algorithms | |
| |
| |
Construction Procedures | |
| |
| |
| |
Quadratic Set Packing Models | |
| |
| |
Problem Statement and Objective | |
| |
| |
Branch-and-Bound Algorithm | |
| |
| |
Manufacturing Layout Solution | |
| |
| |
Factory Project Examples | |
| |
| |
| |
STEP Algorithm | |
| |
| |
Stochastic Examples | |
| |
| |
Algorithm | |
| |
| |
Sampling test and Pairwise Exchange Procedure | |
| |
| |
The Concept of the Sampling Test | |
| |
| |
Computational Results | |
| |
| |
Factory Project Example | |
| |
| |
| |
Summary | |
| |
| |
| |
Exercises | |
| |
| |
References | |
| |
| |
Material Handling Principles, Equipment, and System Design | |
| |
| |
| |
Introduction | |
| |
| |
Motivation | |
| |
| |
| |
Scope and Definitions | |
| |
| |
| |
Principles of Material Handling (PAS1 S 2AGES) | |
| |
| |
Unit Load Principle S2 | |
| |
| |
| |
Designing Material Handling Systems (MHS) | |
| |
| |
| |
Material Handling Equipment | |
| |
| |
Conveyors | |
| |
| |
Monorails, Hoists, and Cranes | |
| |
| |
Industrial Trucks | |
| |
| |
| |
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 | |
| |
| |
| |
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 | |
| |
| |
| |
Summary and Conclusion | |
| |
| |
| |
Exercises | |
| |
| |
References | |
| |
| |
Material Handling Systems Analysis | |
| |
| |
| |
Introduction | |
| |
| |
Motivation | |
| |
| |
| |
Integration of Layout and Material Handling System | |
| |
| |
Fundamental Integration Principle | |
| |
| |
Case Study | |
| |
| |
Addenda to Section III of Project | |
| |
| |
| |
Open Network System Design Tool: GQnet | |
| |
| |
GQnet Basic Assumptions | |
| |
| |
GQnet Algorithm | |
| |
| |
GQnet Computational Results | |
| |
| |
| |
Closed-Loop Conveyor Systems Overview | |
| |
| |
Deterministic Conveyor Model | |
| |
| |
Conveyor Example | |
| |
| |
Stochastic Analytical Approaches | |
| |
| |
Algorithms | |
| |
| |
Computer Experiments | |
| |
| |
| |
Simulation Models | |
| |
| |
Introduction | |
| |
| |
Cellular Methodology | |
| |
| |
Simulation Section Outline | |
| |
| |
Background of Case Study | |
| |
| |
Individual Cell Simulation Model | |
| |
| |
Cell Network Study | |
| |
| |
| |
Warehouse Simulation | |
| |
| |
Motivation | |
| |
| |
Background | |
| |
| |
Problem Description | |
| |
| |
Layout of factory | |
| |
| |
| |
Summary and Conclusions | |
| |
| |
| |
Exercises | |
| |
| |
References | |
| |
| |
Storage and Warehouse Systems | |
| |
| |
| |
Introduction | |
| |
| |
| |
Receiving and shipping | |
| |
| |
Receiving and Putaway Operations | |
| |
| |
Processing Customer Orders | |
| |
| |
Order Picking | |
| |
| |
Packing and Shipping | |
| |
| |
Cross Docking | |
| |
| |
| |
Dedicated and Random Storage | |
| |
| |
Dedicated Storage | |
| |
| |
Random Storage | |
| |
| |
| |
Models for Determining Storage Capacity | |
| |
| |
Service-Level Approach | |
| |
| |
Cost-Based Approach | |
| |
| |
| |
Storage-Capacity Determination | |
| |
| |
Randomized Storage Policy | |
| |
| |
| |
Dock Planning and Design | |
| |
| |
Dock Location | |
| |
| |
Types of Docks | |
| |
| |
Dock Design | |
| |
| |
Dock Levelers | |
| |
| |
Dock Safety | |
| |
| |
| |
Warehouse Systems Design | |
| |
| |
Storage Equipment | |
| |
| |
Carousels | |
| |
| |
Rack Storage Systems | |
| |
| |
| |
Automated Storage and Retrieval Systems (AS/RS) | |
| |
| |
| |
Exercises | |
| |
| |
References | |
| |
| |
Site-Planning Design | |
| |
| |
| |
Introduction | |
| |
| |
Motivation | |
| |
| |
Example Sitting Problem | |
| |
| |
| |
Site-Planning Methodology | |
| |
| |
Objective /Attribute Hierarchy | |
| |
| |
Basic Assumptions | |
| |
| |
First Assumption | |
| |
| |
Second Assumption | |
| |
| |
Third Assumption | |
| |
| |
Fourth Assumption | |
| |
| |
Performance Functions | |
| |
| |
| |
Site-Selection Criteria | |
| |
| |
Physical Criteria | |
| |
| |
Cultural Criteria | |
| |
| |
Functional Criteria | |
| |
| |
| |
Manufacturing Site-Planning Examples | |
| |
| |
Objective Function (Distance or Time) | |
| |
| |
Site-Planning Example | |
| |
| |
| |
Factory Project Case Study | |
| |
| |
Soils | |
| |
| |
Slopes | |
| |
| |
Views Evaluation | |
| |
| |
Site Drainage | |
| |
| |
Final Summary Evaluation | |
| |
| |
Factory Project Site- Planning Example | |
| |
| |
| |
Summary and Conclusions | |
| |
| |
| |
Exercises | |
| |
| |
References | |
| |
| |
Office and Personnel Layout Planning | |
| |
| |
| |
Introduction | |
| |
| |
History | |
| |
| |
Outline of Chapter | |
| |
| |
| |
Office Spatial Organization Problem | |
| |
| |
General Functions of Office | |
| |
| |
| |
Office Space Guidelines | |
| |
| |
Ancillary Space Guidelines | |
| |
| |
Miscellaneous Areas of Offices | |
| |
| |
| |
Personnel Requirements and Office Arrangements | |
| |
| |
Personnel Requirements | |
| |
| |
Types of Office Arrangements | |
| |
| |
Example Office layout | |
| |
| |
| |
Utility Company office Case Study | |
| |
| |
Alternative1 | |
| |
| |
Alternative | |
| |
| |
Alternative | |
| |
| |
Alternative | |
| |
| |
Analysis and conclusions | |
| |
| |
| |
Factory Design Project: Section IV. Personnel Requirements and Calculation of Product Total Unit Cost | |
| |
| |
Conceptual Overview | |
| |
| |
Organization of Report | |
| |
| |
Positions and Job Descriptions | |
| |
| |
| |
Factory Design Project: Section V. Office Layout Planning | |
| |
| |
Overall Conceptual Approach | |
| |
| |
Report Organization | |
| |
| |
Selected Office Layout | |
| |
| |
| |
Summary and conclusions | |
| |
| |
| |
Exercises | |
| |
| |
References | |
| |
| |
Final Synthesis | |
| |
| |
| |
Introduction | |
| |
| |
Overview of Chapter | |
| |
| |
Professions Involved in Facilities Planning | |
| |
| |
Leased Facility for Project | |
| |
| |
| |
New vs. Existing Buildings | |
| |
| |
| |
Structural Engineering | |
| |
| |
Roofs and Floors | |
| |
| |
Walls and Columns | |
| |
| |
Building-Code Considerations | |
| |
| |
| |
Heating, Ventilating and Air-Conditioning (HVAC) | |
| |
| |
Electrical/Lighting | |
| |
| |
Plumbing | |
| |
| |
Vertical Transportation | |
| |
| |
| |
Functional Adaptation of Existing Buildings | |
| |
| |
Adaptability | |
| |
| |
Flexibility | |
| |
| |
| |
Building Economics | |
| |
| |
Structural System | |
| |
| |
Architectural | |
| |
| |
Mechanical Systems | |
| |
| |
Administrative Costs | |
| |
| |
Cultural | |
| |
| |
| |
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 | |