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THE IMPORTANCE OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING1

CHAPTER 1 Introduction to Manufacturing Facilities Design and Material Handling1

LEAN THINKING AND LEAN MANUFACTURING4

THE GOALS OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING4

THE MANUFACTURING FACILITIES DESIGN PROCEDURE9

TYPES AND SOURCES OF MANUFACTURING FACILITIES DESIGN PROJECTS11

COMPUTERS AND SIMULATION IN MANUFACTURING FACILITIES DESIGN12

ISO 9000 and Facilities Planning13

GLOSSARY OF MAJOR TERMS14

QUESTIONS16

CHAPTER 2 Sources of lnformation for Manufacturing Facilities Design18

THE MARKETING DEPARTMENT19

THE PRODUCT DESIGN DEPARTMENT21

Inventory Policy28

Lean Thinking and Muda as a Part of Management Policy28

MANAGEMENT POLICY INFORMATION28

Investment Policy29

Starmp Schedule29

Make or Buy Decisions30

Organizational Relationships30

Feasibility Studies31

CONCLUSION32

QUESTIONS33

WHAT IS A TIME STANDARD?34

CHAPTER 3 Time Study34

IMPORTANCE AND USES OF TIME STUDY37

1. How Many Machines Do We Need?38

2. How Many People Should We Hire?39

3. How Much Will Our Product Cost?41

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?43

5. Determine the Assembly Line Balance, Determine the Conveyor Belt Speed, Load the Work Cells with the Correct Amount of Work,and Balance the Work Cells?44

6. How Do We Measure Productivity?44

8. How Can We Select the Best Method or Evaluate Cost Reduction Ideas?46

7. How Can We Pay Our People for Outstanding Performance?46

9. How Do You Evaluate New Equipment Purchases to Justify Their Expense?48

TECHNIQUES OF TIME STUDY48

10. How Do We Develop a Personnel Budget?49

Predetermined Time Standards Systems49

Stopwatch Time Study52

Time Study Procedure and the Step-by-Step Form52

Principles of Elemental Breakdown57

Rating, Leveling, and Normalizing61

ALLOWANCES65

Types of Allowances65

Methods of Applying Allowances68

Work Sampling71

Standard Data72

Expert Opinion Time Standards and Historical Data72

TIME STANDARDS FOR MANUFACTURING FACILITIES DESIGN74

QUESTIONS75

CHAPTER 4 Process Design76

Route Sheets77

FABRICATION: MAKING THE INDIVIDUAL PARTS77

The Number of Machines Needed80

WORK CELL LOAD CHART82

Step-by-Step Procedure for Preparing a Work Cell Load Chart86

ASSEMBLY AND PACKOUT PROCESS ANALYSIS86

The Assembly Chart87

Time Standards Are Required for Every Task87

Paint Conveyor Speed88

Plant Rate and Conveyor Speed88

Assembly Line Balancing90

STEP-BY-STEP PROCEDURE FOR COMPLETING THE ASSEMBLY LINE BALANCING FORM94

CALCULATING THE EFFICIENCY OF THE ASSEMBLY LINE100

Use of Computer Simulation101

LAYOUT ORIENTATION104

QUESTIONS104

CHAPTER 5 Flow Analysis Techniques106

FABRICATION OF INDIVIDUAL PARTS109

String Diagram110

Multi-Column Process Chart112

From-To Chart113

Process Chart117

Step-by-Step Description for the Process Chart117

TOTAL PLANT FLOW121

Flow Diagrams121

The Operations Chart124

Step-by-Step Procedure for Developing a Flow Diagram124

Step-by-Step Procedures for Preparing an Operations Chart126

Flow Process Chart130

Step-by-Step Procedure for Preparing a Flow Process Chart130

COMPUTER-AIDED FLOW DESIGN AND ANALYSIS130

CONCLUSION133

QUESTIONS133

CHAPTER 6 Activity Relationship Analysis137

THE ACTIVITY RELATIONSHIP DIAGRAM138

Determining the Relationship Code140

WORKSHEET141

DIMENSIONLESS BLOCK DIAGRAM142

FLOW ANALYSIS144

COMPUTER-GENERATED ACTIVITY RELATIONSHIP CHART146

QUESTIONS150

CHAPTER 7 Ergonomics and Workstation Design Space Requirement152

WORKSTATION DESIGN152

ERGONOMICS AND THE PRINCIPLES OF MOTION ECONOMY158

Principle 1: Hand Motions159

Principle 2: Basic Motion Types160

Principle 3: Location of Parts and Tools160

Principle 4: Free the Hands from as Much Work as Possible160

Principle 5: Use Gravity163

Principle 6: Operator Safety and Health Considerations165

SPACE DETERMINATION165

QUESTIONS169

The Advantages and Disadvantages of Centralized Receiving and Shipping170

CHAPTER 8 Auxiliary Services Requirement Space170

RECEIVING AND SHIPPING170

The Trucking Industry s Effect on Shipping and Receiving171

The Functions of a Receiving Department171

Facilities Required for Receiving Departments173

Space Requirements for the Receiving Department175

The Functions of a Shipping Department176

Space Requirements for Shipping Departments179

STORAGE180

Just-in-Time Inventories182

Maximizing the Use of the Cubic Space182

Provide Immediate Access to Everything184

Provide Safekeeping191

WAREHOUSING192

Warehouse Design Criteria193

The Functions of a Warehouse194

Procedure for Sales Analysis of ABC Inventory196

ABC Inventory Layout of a Hand Tool Manufacturing Company s Warehouse198

Warehouse Space Determination200

Warehouse Equipment201

Conclusion203

MAINTENANCE AND TOOL ROOM203

UTILITIES204

QUESTIONS205

CHAPTER 9 Employee Services—Space Requirements207

PARKING LOTS208

EMPLOYEE ENTRANCES209

LOCKER ROOMS211

TOILETS AND RESTROOMS212

LUNCH ROOMS215

RECREATION217

DRINKING FOUNTAINS218

AISLES218

MEDICAL FACILITIES219

MISCELLANEOUS EMPLOYEE SERVICES220

BREAK AREAS AND LOUNGES220

QUESTIONS222

CHAPTER 10 Material Handling223

COST JUSTIFICATION224

Sample Material Handling Cost Problem224

GOALS OF MATERIAL HANDLING225

THE 20 PRINCIPLES OF MATERIAL HANDLING226

1. The Planning Principle226

2. The Systems Principle227

3. The Material Flow Principle228

4. The Work Simplification Principle228

5. Use Gravity229

6. Maximize the Building Code229

7. Unit Size Principle230

8. Mechanization Principle231

9. Automation Principle231

10. Equipment Selection Principle231

11. The Standardization Principle233

12. The Adaptability Principle234

13. The Dead Weight Principle234

14. The Utilization Principle234

15. The Maintenance Principle234

16. The Obsolescence Principle235

17. The Control Principle235

18. The Capacity Principle235

20. The Safety Principle236

19. The Performance Principle236

THE MATERIAL HANDLING PROBLEM-SOLVING PROCEDURE237

MATERIAL HANDLING CHECKLIST238

QUESTIONS241

CHAPTER 11 Material Handling Equipment243

RECEIVING AND SHIPPING244

Receiving and Shipping Docks244

Dock Equipment246

Fork Trucks250

Moving Equipment250

Telescopic Conveyor256

Bridge Cranes256

Weight Scale257

Systems Required on Shipping and Receiving Docks257

STORES260

Storage Units260

Stores Mobile Equipment262

Systems Required for Stores Department267

Tubs and Baskets269

FABRICATION269

Shop Containers269

Workstation Material Handling Devices273

Manipulators and Lifting Devices273

Mobile Fabrication Equipment284

ASSEMBLY AND PAINT289

Belt Conveyors291

Slat Conveyor292

Powered Roller Conveyor292

Car-Type Conveyor292

Tow Conveyor294

Overhead Trolley Conveyor294

Power and Free Conveyor295

PACKOUT298

Box Formers298

Automatic Taping, Gluing, and Stapling298

Palletizers298

Pick and Place Robots300

Banding300

Stretch Wrap300

WAREHOUSING302

Picking Carts302

Gravity Flow Bins303

Tractor-Trailer Picking Cart303

Rotary Conveyor Bins305

Clamp Trucks305

Vertical Warehouse and Picking Cars307

Packing Station307

Shipping Containers308

BULK MATERIAL HANDLING309

Bulk Material Conveyors310

COMPUTER-INTEGRATED MATERIAL HANDLING SYSTEMS313

Cross-Docking and Flow-Through314

QUESTIONS316

CHAPTER 12 Office Layout Techniques and Space Requirements317

GOALS OF OFFICE LAYOUT DESIGN317

TYPES OF OFFICE SPACE318

Supervisors Offices319

Open Office Space320

Conventional Offices322

The Modem Office323

SPECIAL REQUIREMENTS AND CONSIDERATIONS OF SOME OFFICES325

THE TECHNIQUES OF OFFICE LAYOUT329

The Organizational Chart330

Flowchart331

Communications Force Diagram332

Activity Relationship Diagram335

Activity Worksheet335

Dimensionless Block Diagram336

Office Space Determination338

Detailed Master Layout339

QUESTIONS341

CHAPTER 13 Area Allocation342

SPACE REQUIREMENTS PLANNING: STEP ONE342

BUILDING SIZE DETERMINATION345

DIMENSIONLESS BLOCK DIAGRAM345

AREA ALLOCATION PROCEDURE345

OFFICE AREA ALLOCATION347

QUESTIONS351

PLOT PLAN352

CHAPTER 14 Facilities Design—The Layout352

Plant Layout Methods355

MASTER PLAN355

Advanced Computer Systems361

PLANT LAYOUT PROCEDURE—TOOLBOX PLANT366

Office Layout for Toolbox Plant368

EVALUATION368

QUESTIONS373

INTRODUCTION374

CHAPTER 15 Application of Computer Simulation and Modeling374

DEFINING COMPUTER SIMULATION375

ADVANTAGES AND DISADVANTAGES OF SIMULATION376

SIMULATION IN FACILITIES PLANNING376

HOW SIMULATION WORKS377

AN OVERVIEW OF LAYOUT AND SIMULATION SOFTWARE379

COMPUTER-AIDED LAYOUT DESIGN379

Computer-Assisted Layout Performance Analysis381

Simulation in Manufacturing386

CASE STUDIES386

Waste Handling and Simulation387

Simulation and Health Care387

QUESTIONS388

CHAPTER 16 Selling the Layout389

THE PROJECT REPORT389

THE PRESENTATION392

ADJUSTMENTS392

APPROVAL392

Sourcing393

THE REST OF THE PROJECT393

Installation394

Engineering Plot394

Production Start394

Debugging and Follow-Up395

Conclusion395

Answers397

Index411