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Copyright, ii
Dedication, iii
Preface, xiii
Chapter 1. Fundamental Principles of Facilities Planning and Design, 1
1.1. Introduction, 1
What Is Design?, 2
Characteristics of Design Problems, 2
Design Program, 5
Design Process, 5
1.2. Hierarchical Cycle of Facilities Planning, 7
1.3. Objectives of Facilities Planning, 7
Issue-Based Information Systems (IBIS), 8
Site-Planning IBIS Example, 8
Decision-Support (DSS) Computer Programs, 10
1.4. Mathematical Models in Facility Planning, 11
1.5. Manufacturing Systems Concepts, 15
1.6. Types of Basic Manufacturing Layouts, 17
Fixed-Position Layout, 17
Product Layout Process, 17
Process Layout Process, 18
Cellular Layout Process, 19
1.7. Service Systems, 21
1.8. Renovation or Reengineered Facilities, 23
1.9. Facilities Planning and Design Constraints, 23
1.10. Summary and Conclusion, 23
1.11. Exercises, 24
References, 26
Chapter 2. Factory Layout and Material Handling Project, 28
2.1. Introduction, 28
2.2. Project Overview, 29
Computerized Format Files, 31
Basic Documents, 31
Project Report, 32
2.3. Section I: Product Analysis, 32
Production Drawings, 33
Parts List and Identification System, 33
Assembly Flowchart, 34
2.4. Section II: Parts Manufacturing, 34
Route Sheets, 35
Machine Requirements and Costs, 35
Machine Requirements, 35
Machine Costs, 36
Material Requirements, 36
Machine Drawings, 37
2.5. Section III: Layout Planning, 37
Layout Planning Charts, 37
Material Handling Requirements and Costs, 38
2.6. Section IV: Personnel Planning, 39
Personnel Requirements and Costs, 39
Unit Costs, 39
2.7. Section V: Office Layout, 39
2.8. Section VI: Recommended Plant Layout, 40
Chapter 3. Product Design and Process Planning, 41
3.1. Market Research, 42
Types of Market Research, 42
Qualitative Forecasting Methods, 43
Quantitative Forecasting Methods, 44
3.2. Product Design, 45
Product Design Process, 45
Bill of Materials or Part List, 48
Component Part Drawings, 51
Assembly Drawing, 51
3.3. Product Design Tools, 52
Concurrent Engineering, 52
Quality Function Deployment, 52
Value Analysis, 53
3.4. Factory Design Project: Section I. Product Design, 54
What Product?, 54
What Parts Compose the Product?, 55
Guidelines, 55
Report Organization, 56
3.5. Process Planning, 56
Process Planning Procedure, 56
Selection of Manufacturing Processes, 57
Sequencing of Manufacturing Processes, 59
3.6. Types of Process Planning, 61
Manual Process Planning, 65
Variant Process Planning, 67
Generative Process Planning (GPP), 67
Semigenerative Process Planning, 67
Computer-Aided Manufacturing, 68
3.7. Schedule Design, 69
3.8. Factory Design Project: Section II. Process Design, 71
Guidelines, 71
Organization of Report, 71
3.9. Summary, 74
3.10. Exercises, 74
References, 77
Chapter 4. Layout Planning Procedures, 78
4.1. Introduction, 79
4.2. Systematic Layout Planning, 80
4.3. From–To Program, 84
4.4. Production Flow Analysis, 85
Overview of Conceptual Approach, 85
Integration of SLP and PFA, 88
4.5. Flow Planning, 90
4.6. Layout Planning Chart, 93
4.7. Space Requirements, 94
4.8. Facility Layout Program (FLAP), 96
Description and Illustration of Procedure, 97
Facilities Layout Program (FLAP): User Instructions, 101
4.9. Summary, 110
4.10. Exercises, 112
References, 114
Chapter 5. Location Models in Facility Planning, 115
5.1. Single-Facility Location Model, 116
Minisum Location Problem with Rectilinear Distances, 117
Extension to Rectangular Areas, 126
Minimax Location Model for Single Facility, 128
Minimax Location Problem for Rectilinear Distances, 128
5.2. Location–Allocation Problem, 132
Mathematical Model, 132
Solution Procedure, 132
5.3. Quadratic Assignment Problem (QAP), 135
5.4. Heuristic Methods for Solving the QAP, 136
Incremental Cost after Adding a New Facility, 137
Pairwise Interchange, 137
Heuristic Construction Procedure, 138
Heuristic Improvement Procedure, 138
5.5. Exercises, 144
Chapter 6. Computerized Layout Procedures, 148
6.1. Introduction, 148
6.2. Scope and Definitions, 150
6.3. Facility Layout Software Issues, 151
6.4. Exact QAP and GTLN Optimization Procedures, 153
Exact Graph-Theoretic Procedures, 155
6.5. Heuristic Procedures, 156
Improvement Procedures, 157
Improvement Algorithms, 157
Construction Procedures, 159
6.6. Quadratic Set Packing Models, 164
Problem Statement and Objective, 165
Branch-and-Bound Algorithm, 167
Manufacturing Layout Solution, 172
Factory Project Examples, 177
6.7. STEP Algorithm, 180
Stochastic Example, 184
Algorithm, 184
Sampling Test and Pairwise Exchange Procedure, 185
The Concept of the Sampling Test, 187
Computational Results, 188
Factory Project Example, 189
6.8. Summary, 190
6.9. Exercises, 191
References, 194
Chapter 7. Material Handling Principles, Equipment, and System Design, 199
7.1. Introduction, 200
Motivation, 200
7.2. Scope and Definitions, 201
7.3. Principles of Material Handling (PAS_{1}S_{2}AGES_{3}), 202
Unit Load Principle S_2, 203
7.4. Designing Material Handling Systems (MHS), 204
7.5. Material Handling Equipment, 205
Conveyors, 206
Monorails, Hoists, and Cranes, 218
Industrial Trucks, 222
7.6. MHS Decision-Support Tool, 233
Architecture of the Application, 233
The Knowledge Base, 235
Development of Knowledge Base, 235
Developing the Decision-Support System, 235
Developing Inference Chains, 237
Advantages of DSS, 237
Two-Step Approach, 237
Limitations of Existing Expert Systems, 237
Decision-Support System for Material Handling Equipment Selection, 237
Flow of the Application, 239
DSS Stage II for Cranes, 241
Final Synthesis, 242
7.7. Factory Design Project: Section III. Layout Planning and Material Handling, 242
Layout Planning Chart, 243
Material Handling Requirements, 243
Material Handling Costs, 244
Proposed Layout, 245
Sample Calculations, 245
Report Organization, 245
Initial Layout, 246
Material Handling Requirements and Costs, 247
7.8. Summary and Conclusions, 250
7.9. Exercises, 251
References, 252
Chapter 8. Material Handling Systems Analysis, 254
8.1. Introduction, 254
Motivation, 255
Outline of Chapter, 256
8.2. Integration of Layout and the Material Handling System, 257
Fundamental Integration Principles, 257
Case Study, 262
Addenda to Section III of Project, 264
8.3. Open Network System Design Tool: GQnet, 266
GQnet Basic Assumptions, 267
GQnet Algorithm, 269
GQnet Computational Results, 273
8.4. Closed-Loop Conveyor Systems Overview, 283
Deterministic Conveyor Model, 283
Conveyor Example, 286
Stochastic Analytical Approaches, 290
Algorithms, 291
Computer Experiments, 293
8.5. Simulation Models, 301
Introduction, 301
Cellular Methodology, 301
Simulation Section Outline, 302
Background of Case Study, 302
Individual Cell Simulation Model, 305
Cell Network Study, 308
8.6. Warehouse Simulation, 312
Motivation, 312
Background, 312
Problem Description, 313
Layout of Factory, 313
8.7. Summary and Conclusions, 317
8.8. Exercises, 318
References, 324
Chapter 9. Storage and Warehouse Systems, 327
9.1. Introduction, 327
9.2. Receiving and Shipping, 328
Receiving and Putaway Operations, 328
Processing Customer Orders, 329
Order Picking, 329
Packing and Shipping, 331
Cross Docking, 331
9.3. Dedicated and Random Storage, 332
Dedicated Storage, 332
Random Storage, 335
9.4. Models for Determining Storage Capacity, 335
Service-Level Approach, 335
Cost-Based Approach, 335
9.5. Storage-Capacity Determination, 337
Randomized Storage Policy, 337
Dedicated Storage Policy, 338
9.6. Dock Planning and Design, 340
Dock Location, 341
Types of Docks, 342
Dock Design, 342
Dock Levelers, 343
Dock Safety, 346
9.7. Warehouse Systems Design, 347
Storage Equipment, 347
Carousels, 347
Rack Storage Systems, 349
9.8. Automated Storage and Retrieval Systems (AS/RS), 355
9.9. Exercises, 357
References, 359
Chapter 10. Site-Planning Design, 361
10.1. Introduction, 361
Motivation, 364
Example Siting Problem, 364
10.2. Site-Planning Methodology, 365
Objective/Attribute Hierarchy, 366
Basic Assumptions, 367
First Assumption, 368
Second Assumption, 368
Third Assumption, 369
Fourth Assumption, 370
Performance Functions, 371
10.3. Site-Selection Criteria, 375
Physical Criteria, 375
Cultural Criteria, 380
Functional Criteria, 384
10.4. Manufacturing Site-Planning Examples, 391
Objective Function (Distance or Time), 391
Site-Planning Example, 391
10.5. Factory Project Case Study, 394
Soils, 395
Slopes, 395
Views Evaluation, 396
Site Accessibility, 396
Noise Evaluation, 396
Site-Development Costs, 396
Site Drainage, 397
Final Summary Evaluation, 397
Factory Project Site-Plan Example, 398
10.6. Summary and Conclusions, 398
10.7. Exercises, 400
References, 405
Appendix: Site-Planning Issues, 406
Geology Planning Issues, 406
Hydrology Planning Issues, 407
Climactic Planning Issues, 407
Topographic Planning Issues, 407
Ecological Planning Issues, 407
Cultural Planning Issues, 408
Financial Planning Issues, 408
Image Planning Issues, 408
Land Utilization Planning Issues, 408
Administrative Planning Issues, 409
Accessibility Planning Issues, 409
Adaptability Planning Issues, 410
Site Utility Planning Issues, 410
Chapter 11. Office and Personnel Layout Planning, 411
11.1. Introduction, 411
History of Offices, 412
Outline of Chapter, 413
11.2. Office Spatial Organization Problem, 413
General Functions of Office, 415
Organization Chart, 416
11.3. Office Space Guidelines, 416
Ancillary Space Guidelines, 423
Miscellaneous Areas or Offices, 425
11.4. Personnel Requirements and Office Arrangements, 425
Personnel Requirements, 425
Types of Office Arrangements, 426
Example Office Layout, 429
11.5. Utility Company Office Case Study, 433
Alternative 1, 434
Alternative 2, 435
Alternative 3, 435
Alternative 4, 435
Analysis and Conclusions, 437
11.6. Factory Design Project: Section IV. Personnel Requirements and Calculation of Product Total Unit Cost, 437
Conceptual Overview, 439
Organization of Report, 440
Positions and Job Descriptions, 440
11.7. Factory Design Project: Section V. Office Layout Planning, 446
Overall Conceptual Approach, 446
Report Organization, 446
Selected Office Layout, 448
11.8. Summary and Conclusions, 451
11.9. Exercises, 451
References, 453
Chapter 12. Final Synthesis, 454
12.1. Introduction, 454
Overview of Chapter, 454
Professions Involved in Facilities Planning, 455
Leased Facility for Project, 456
12.2. New vs. Existing Buildings, 457
12.3. Structural Engineering, 461
Roofs and Floors, 462
Walls and Columns, 463
Building-Code Considerations:, 464
12.4. Heating, Ventilating and Air-Conditioning (HVAC), 465
Electrical/Lighting, 466
Plumbing, 467
Vertical Transportation, 467
12.5. Functional Adaptation of Existing Buildings, 468
Adaptability, 468
Flexibility, 469
12.6. Building Economics, 470
Structural System, 471
Architectural, 471
Mechanical Systems, 471
Administrative Costs, 472
Cultural, 473
Factory Renovation Project, 474
12.7. Factory Design Project: Section VI. Recommended Plant Layout, 477
Factory Report Organization, 477
Plant Layout Summary Sheet, 478
Checklist for Final Report, 478
Breakeven-Point Analysis, 481
Factory Project Presentation Guidelines, 484
References, 486
Appendix: Renovation vs. New Construction Planning Issues, 486
Structural, 486
Mechanical/Electrical, 487
Functional, 487
Financial, 487
Cultural, 488
Appendix. Decision-Support Methodology (DSM), 489
Introduction, 489
Modules, 490
Material Selection and Cost Estimation, 490
Machine Selection and Cost Estimation, 490
Material Handling Equipment Selection and Cost Determination, 490
Labor Cost Determination, 491
General Question Form, 491
Part Details Form, 491
Machine Form, 495
Personnel Form, 495
Part Cost Results Form, 496
Index, 498

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