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Facilities Planning and Design, CourseSmart eTextbook

By Alberto Garcia-Diaz, J. MacGregor Smith

Published by Prentice Hall

Published Date: Feb 12, 2008

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For undergraduate courses in facilities planning and material handling.


Based on ten years' teaching experience, this text takes a practical, teachable approach to facilities planning and design. A class design project centered on a factory incorporates the theoretical aspects of facilities planning and design. Motivating and illustrating mathematical models wherever possible, the text explores facilities planning, capstone design, and even simulation modelling.

Table of Contents

Fundamental Principles of Facilities Planning and Design


1.1  Introduction

 What is Design

 Characteristics of Design Problems

 Design Program

 Design Process

1.2  Hierarchical Cycle of Facilities Planning

1.3  Objectives of Facilities Planning

  Issue-Based Information Systems

  Site-Planning IBIS Example

  Decision-Support (DSS) Computer Programs

1.4  Mathematical Models in Facility Planning

1.5  Manufacturing Systems Concepts

1.6  Types of Basic Manufacturing Layouts

  Fixed-Position Layout

  Product Layout Process

  Process Layout Process

  Cellular Layout Process

1.7  Service Systems

1.8  Renovation or Reengineered Facilities

1.9  Facilities Planning and Design Constraints

1.10 Summary and Conclusion

1.11 Exercises



Factory Layout and Material Handling Project


2.1 Introduction

2.2 Project Overview

     Computerized Format Files

     Basic Documents

     Project Report

2.3 Section I: Product Analysis

      Production Drawings

      Parts List and Identification System

      Assembly Flowchart

2.4 Section II: Parts Manufacturing

      Route Sheets

      Machine Requirements and Costs

      Machine Requirements

      Machine Costs

      Material Requirements

      Machine Drawings

2.5 Section III: Layouts Planning

      Layout Planning Charts

      Material handling Requirements and Costs

2.6 Section IV: Personnel Planning

      Personnel Requirements and Costs

      Unit Costs

2.7 Section V: Office Layout

2.8 Section VI: Recommended Plant Layout


Product Design and Process Planning


3.1 Market Research

      Types of Market Research

      Qualitative Forecasting Methods

      Quantitative Forecasting Methods

3.2 Product Design

      Product Design Process

      Bill of Materials or part List

      Component Part Drawing

      Assembly Drawing

3.3 Product Design

      Concurrent Engineering

      Quality Function Deployment

       Value Analysis

3.4 Factory Design Project: Section I. Product Design

      What Product?

      What Parts Compose the Product?


        Report Organization

3.5 Process Planning

      Process Planning Procedure

      Selection of Manufacturing

      Sequencing of Manufacturing Processes

3.6 Types of Process Planning

      Manual Process Planning

      Variant Process Planning

      Generative Process Planning

      Generative Process Planning (GPP)

      Semigenerative Process Planning

      Computer-Aided Manufacturing

3.7 Schedule

3.8 Factory Design Project: Section II. Process Design


     Organization of Report

3.9 Summary

3.10 Exercises



Layout Planning Procedures


4.1 Introduction

4.2 Systematic Layout Planning

4.3 From-To Program

4.4 Production Flow Analysis

      Overview of Conceptual Approach

       Integration of SLP and PFA

4.5 Flow Planning

4.6 Layout Planning Chart

4.7 Space Requirements

4.8 Facility Layout (FLAP)

      Description and Illustration of Procedure

      Facilities layout Program (FLAP): User Instructions

4.9 Summary

4.10 Exercises



Location Models in facility Planning


5.1 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

5.2 Location-Allocation Problem

      Mathematical Model

      Solution Procedure

5.3 Quadratic Assignment Problem (QAP)

5.4 Heuristic Methods for Solving the QAP

      Incremental Cost after adding a new facility

      Pairwise Interchange

      Heuristic Construction Procedure

      Heuristic Improvement Procedure

5.5 Exercises


Computerized Layout Procedures


6.1 Introduction

6.2 Scope and Definitions

6.3 Facility Layout Software Issues

6.4 Exact QAP and GTLN Optimization Procedures

      Exact Graph-Theoretic Procedures

6.5 Heuristic Procedures

      Improvement Procedures

      Improvement Algorithms

      Construction Procedures

6.6 Quadratic Set Packing Models

       Problem Statement and Objective

       Branch-and-Bound Algorithm

       Manufacturing Layout Solution

       Factory Project Examples

6.7 STEP Algorithm

      Stochastic Examples


      Sampling test and Pairwise Exchange Procedure

      The Concept of the Sampling Test

      Computational Results

      Factory Project Example

6.8 Summary

6.9 Exercises



Material Handling Principles, Equipment, and System Design


7.1 Introduction


7.2 Scope and Definitions

7.3 Principles of Material Handling (PAS1 S 2AGES)

      Unit Load Principle S2

7.4 Designing Material Handling Systems (MHS)

7.5 Material Handling Equipment


      Monorails, Hoists, and Cranes

      Industrial Trucks

7.6 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

7.7 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

7.8 Summary and Conclusion

7.9 Exercises



Material Handling Systems Analysis


8.1 Introduction


8.2 Integration of Layout and Material Handling System

      Fundamental Integration Principle

      Case Study

      Addenda to Section III of Project

8.3 Open Network System Design Tool: GQnet

     GQnet Basic Assumptions

      GQnet Algorithm

      GQnet Computational Results

8.4 Closed-Loop Conveyor Systems Overview

      Deterministic Conveyor Model

      Conveyor Example

      Stochastic Analytical Approaches


      Computer Experiments

8.5 Simulation Models


      Cellular Methodology

      Simulation Section Outline

      Background of Case Study

      Individual Cell Simulation Model

      Cell Network Study

8.6 Warehouse Simulation



       Problem Description

       Layout of factory

8.7 Summary and Conclusions

8.8 Exercises



Storage and Warehouse Systems


9.1 Introduction

9.2 Receiving and shipping

      Receiving and Putaway Operations

      Processing Customer Orders

      Order Picking

      Packing and Shipping

      Cross Docking

9.3 Dedicated and Random Storage

      Dedicated Storage

      Random Storage

9.4 Models for Determining Storage Capacity

      Service-Level Approach

      Cost-Based Approach

9.5 Storage-Capacity Determination

      Randomized Storage Policy

9.6 Dock Planning and Design

      Dock Location

      Types of Docks

      Dock Design

      Dock Levelers

      Dock Safety

9.7 Warehouse Systems Design

      Storage Equipment


      Rack Storage Systems

9.8 Automated Storage and Retrieval Systems (AS/RS)

9.9 Exercises



Site-Planning Design


10.1 Introduction


       Example Sitting Problem

10.2 Site-Planning Methodology

        Objective /Attribute Hierarchy

        Basic Assumptions

        First Assumption

        Second Assumption

        Third Assumption

        Fourth Assumption

        Performance Functions

10.3 Site-Selection Criteria

        Physical Criteria

        Cultural Criteria

        Functional Criteria

10.4 Manufacturing Site-Planning Examples

        Objective Function (Distance or Time)

        Site-Planning Example

10.5 Factory Project Case Study



        Views Evaluation

        Site Drainage

        Final Summary Evaluation

        Factory Project Site- Planning Example

10.6 Summary and Conclusions

10.7 Exercises



Office and Personnel Layout Planning


11.1 Introduction


 Outline of Chapter

11.2 Office Spatial Organization Problem

        General Functions of Office

11.3 Office Space Guidelines

Ancillary Space Guidelines

Miscellaneous Areas of Offices

11.4 Personnel Requirements and Office Arrangements

        Personnel Requirements

 Types of Office Arrangements

 Example Office layout

11.5 Utility Company office case Study


Alternative 2

Alternative 3

Alternative 4

Analysis and conclusions

11.6 Factory Design Project: Section IV. Personnel Requirements and Calculation of Product Total Unit Cost

       Conceptual Overview

       Organization of Report

       Positions and Job Descriptions

11.7 Factory Design Project: Section V. Office Layout Planning

        Overall Conceptual Approach

        Report Organization

        Selected Office Layout

11.8 Summary and conclusions

11.9 Exercises



Final Synthesis


12.1 Introduction

       Overview of Chapter

       Professions Involved in Facilities Planning

       Leased Facility for Project

12.2 New vs. Existing Buildings

12.3 Structural Engineering

        Roofs and Floors

        Walls and Columns

         Building-Code Considerations

12.4 Heating, Ventilating and Air-Conditioning (HVAC)



        Vertical Transportation

12.5 Functional Adaptation of Existing Buildings



12.6 Building Economics

        Structural System


        Mechanical Systems

        Administrative Costs


12.7 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


        Appendix: Renovation vs. New Construction Planning Issues





















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