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Full Description
This book takes a modern view of the field of facilities planning and design, along with a unified body of relevant knowledge. KEY TOPICS: Motivating and illustrating mathematical models wherever possible, the book explores facilities planning, capstone design, and even simulation modelling. A design project incorporates the theoretical aspects of facilities planning and design. The book also covers decision-support methodology and computerized procedures. MARKET: For industrial engineers, facilities managers, and plant managers.
Contents
Fundamental Principles of Facilities Planning and Design1.1 IntroductionWhat is DesignCharacteristics of Design ProblemsDesign ProgramDesign Process1.2 Hierarchical Cycle of Facilities Planning1.3 Objectives of Facilities PlanningIssue-Based Information SystemsSite-Planning IBIS ExampleDecision-Support (DSS) Computer Programs1.4 Mathematical Models in Facility Planning1.5 Manufacturing Systems Concepts1.6 Types of Basic Manufacturing LayoutsFixed-Position LayoutProduct Layout ProcessProcess Layout ProcessCellular Layout Process1.7 Service Systems1.8 Renovation or Reengineered Facilities1.9 Facilities Planning and Design Constraints1.10 Summary and Conclusion1.11 ExercisesReferencesFactory Layout and Material Handling Project2.1 Introduction2.2 Project OverviewComputerized Format FilesBasic DocumentsProject Report2.3 Section I: Product AnalysisProduction DrawingsParts List and Identification SystemAssembly Flowchart2.4 Section II: Parts ManufacturingRoute SheetsMachine Requirements and CostsMachine Requirements Machine CostsMaterial RequirementsMachine Drawings2.5 Section III: Layouts PlanningLayout Planning Charts Material handling Requirements and Costs2.6 Section IV: Personnel Planning Personnel Requirements and CostsUnit Costs2.7 Section V: Office Layout2.8 Section VI: Recommended Plant LayoutProduct Design and Process Planning3.1 Market ResearchTypes of Market ResearchQualitative Forecasting MethodsQuantitative Forecasting Methods3.2 Product Design Product Design Process Bill of Materials or part ListComponent Part DrawingAssembly Drawing3.3 Product Design Concurrent EngineeringQuality Function DeploymentValue Analysis 3.4 Factory Design Project: Section I. Product DesignWhat Product?What Parts Compose the Product?GuidelinesReport Organization 3.5 Process PlanningProcess Planning ProcedureSelection of ManufacturingSequencing of Manufacturing Processes 3.6 Types of Process PlanningManual Process PlanningVariant Process PlanningGenerative Process PlanningGenerative Process Planning (GPP)Semigenerative Process PlanningComputer-Aided Manufacturing3.7 Schedule3.8 Factory Design Project: Section II. Process DesignGuidelinesOrganization of Report3.9 Summary3.10 ExercisesReferencesLayout Planning Procedures4.1 Introduction4.2 Systematic Layout Planning4.3 From-To Program4.4 Production Flow AnalysisOverview of Conceptual ApproachIntegration of SLP and PFA4.5 Flow Planning4.6 Layout Planning Chart4.7 Space Requirements4.8 Facility Layout (FLAP)Description and Illustration of ProcedureFacilities layout Program (FLAP): User Instructions4.9 Summary4.10 Exercises ReferencesLocation Models in facility Planning5.1 Single-Facility Location ModelMinisum Location Problem with Rectilinear Distances Extension to Rectangular Areas Minimax Location Model for Single FacilityMinimax Location Problem for Rectilinear Distances5.2 Location-Allocation ProblemMathematical ModelSolution Procedure5.3 Quadratic Assignment Problem (QAP)5.4 Heuristic Methods for Solving the QAPIncremental Cost after adding a new facilityPairwise Interchange Heuristic Construction ProcedureHeuristic Improvement Procedure5.5 ExercisesComputerized Layout Procedures6.1 Introduction6.2 Scope and Definitions6.3 Facility Layout Software Issues6.4 Exact QAP and GTLN Optimization ProceduresExact Graph-Theoretic Procedures 6.5 Heuristic ProceduresImprovement ProceduresImprovement AlgorithmsConstruction Procedures 6.6 Quadratic Set Packing ModelsProblem Statement and Objective Branch-and-Bound AlgorithmManufacturing Layout Solution Factory Project Examples6.7 STEP AlgorithmStochastic ExamplesAlgorithmSampling test and Pairwise Exchange ProcedureThe Concept of the Sampling TestComputational ResultsFactory Project Example6.8 Summary6.9 ExercisesReferencesMaterial Handling Principles, Equipment, and System Design7.1 Introduction Motivation 7.2 Scope and Definitions 7.3 Principles of Material Handling (PAS1 S 2AGES)Unit Load Principle S27.4 Designing Material Handling Systems (MHS)7.5 Material Handling EquipmentConveyorsMonorails, Hoists, and CranesIndustrial Trucks7.6 MHS Decision-Support ToolArchitecture of the Application The Knowledge BaseDevelopment of Knowledge BaseDeveloping the Decision-Support System Advantages of DSSTwo-Step ApproachLimitations of Existing Expert Systems Decision-Support System for Material Handling Equipment Selection Flow of the Application DSS Stage II for CranesFinal Synthesis 7.7 Factory Design Project: Section III. Layout Planning and Material Handling Layout Planning ChartMaterial Handling Requirements Material Handling CostsProposed Layout Sample CalculationsReport Organization Initial LayoutMaterial handling Requirements and Costs7.8 Summary and Conclusion7.9 ExercisesReferencesMaterial Handling Systems Analysis8.1 Introduction Motivation 8.2 Integration of Layout and Material Handling SystemFundamental Integration Principle Case StudyAddenda to Section III of Project8.3 Open Network System Design Tool: GQnetGQnet Basic Assumptions GQnet AlgorithmGQnet Computational Results8.4 Closed-Loop Conveyor Systems OverviewDeterministic Conveyor Model Conveyor Example Stochastic Analytical Approaches AlgorithmsComputer Experiments8.5 Simulation Models Introduction Cellular MethodologySimulation Section OutlineBackground of Case Study Individual Cell Simulation Model Cell Network Study8.6 Warehouse Simulation Motivation Background Problem DescriptionLayout of factory 8.7 Summary and Conclusions8.8 ExercisesReferencesStorage and Warehouse Systems9.1 Introduction 9.2 Receiving and shipping Receiving and Putaway OperationsProcessing Customer OrdersOrder PickingPacking and Shipping Cross Docking9.3 Dedicated and Random Storage Dedicated Storage Random Storage9.4 Models for Determining Storage CapacityService-Level ApproachCost-Based Approach9.5 Storage-Capacity DeterminationRandomized Storage Policy9.6 Dock Planning and DesignDock Location Types of DocksDock DesignDock LevelersDock Safety 9.7 Warehouse Systems DesignStorage Equipment CarouselsRack Storage Systems9.8 Automated Storage and Retrieval Systems (AS/RS)9.9 ExercisesReferencesSite-Planning Design10.1 Introduction Motivation Example Sitting Problem10.2 Site-Planning MethodologyObjective /Attribute HierarchyBasic Assumptions First AssumptionSecond Assumption Third Assumption Fourth Assumption Performance Functions10.3 Site-Selection Criteria Physical Criteria Cultural Criteria Functional Criteria 10.4 Manufacturing Site-Planning ExamplesObjective Function (Distance or Time)Site-Planning Example 10.5 Factory Project Case StudySoils Slopes Views Evaluation Site Drainage Final Summary Evaluation Factory Project Site- Planning Example10.6 Summary and Conclusions 10.7 ExercisesReferencesOffice and Personnel Layout Planning 11.1 IntroductionHistory Outline of Chapter11.2 Office Spatial Organization ProblemGeneral Functions of Office11.3 Office Space GuidelinesAncillary Space GuidelinesMiscellaneous Areas of Offices 11.4 Personnel Requirements and Office Arrangements Personnel Requirements Types of Office ArrangementsExample Office layout 11.5 Utility Company office case StudyAlternative1Alternative 2Alternative 3Alternative 4Analysis and conclusions11.6 Factory Design Project: Section IV. Personnel Requirements and Calculation of Product Total Unit CostConceptual Overview Organization of Report Positions and Job Descriptions11.7 Factory Design Project: Section V. Office Layout Planning Overall Conceptual Approach Report Organization Selected Office Layout 11.8 Summary and conclusions11.9 ExercisesReferencesFinal Synthesis12.1 IntroductionOverview of ChapterProfessions Involved in Facilities PlanningLeased Facility for Project 12.2 New vs. Existing Buildings12.3 Structural Engineering Roofs and FloorsWalls and Columns Building-Code Considerations12.4 Heating, Ventilating and Air-Conditioning (HVAC)Electrical/LightingPlumbing Vertical Transportation12.5 Functional Adaptation of Existing BuildingsAdaptabilityFlexibility12.6 Building Economics Structural System Architectural Mechanical Systems Administrative CostsCultural 12.7 Factory Design Project: Section VI. Recommended Plant LayoutFactory Report Organization Plant layout Summary Sheet Checklist for Final ReportBreakeven-Point AnalysisFactory Project Presentation Guidelines ReferencesAppendix: Renovation vs. New Construction Planning IssuesStructural Mechanical/Electrical Functional FinancialCultural
