Manufacturing facilities location, planning, and design
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| 008 | 080923s2008 xxuad|| |||| 00||| eng d | ||
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| 020 | |a 9781420044225 |9 978-1-4200-4422-5 | ||
| 035 | |a (OCoLC)635922659 | ||
| 035 | |a (DE-599)HBZHT015814352 | ||
| 040 | |a DE-604 |b ger |e aacr | ||
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| 084 | |a QP 550 |0 (DE-625)141903: |2 rvk | ||
| 100 | 1 | |a Sule, Dileep R. |e Verfasser |4 aut | |
| 245 | 1 | 0 | |a Manufacturing facilities |b location, planning, and design |c Dileep R. Sule |
| 250 | |a 3. ed. | ||
| 264 | 1 | |a Boca Raton [u.a.] |b CRC Press |c 2008 | |
| 300 | |a 799 S. |b Ill., graph. Darst. | ||
| 336 | |b txt |2 rdacontent | ||
| 337 | |b n |2 rdamedia | ||
| 338 | |b nc |2 rdacarrier | ||
| 500 | |a Includes bibliographical references and index | ||
| 650 | 4 | |a Factories |x Design and construction | |
| 650 | 4 | |a Factories |x Location | |
| 650 | 0 | 7 | |a Fertigungsanlage |0 (DE-588)4140388-5 |2 gnd |9 rswk-swf |
| 650 | 0 | 7 | |a Diskette |0 (DE-588)4122115-1 |2 gnd |9 rswk-swf |
| 650 | 0 | 7 | |a Anlagenwirtschaft |0 (DE-588)4198888-7 |2 gnd |9 rswk-swf |
| 650 | 0 | 7 | |a Fabrikplanung |0 (DE-588)4134388-8 |2 gnd |9 rswk-swf |
| 650 | 0 | 7 | |a Planung |0 (DE-588)4046235-3 |2 gnd |9 rswk-swf |
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| 689 | 1 | 0 | |a Fertigungsanlage |0 (DE-588)4140388-5 |D s |
| 689 | 1 | 1 | |a Planung |0 (DE-588)4046235-3 |D s |
| 689 | 1 | |5 DE-604 | |
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| 943 | 1 | |a oai:aleph.bib-bvb.de:BVB01-016733255 | |
Datensatz im Suchindex
| _version_ | 1819744169245016064 |
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| adam_text | Contents
Preface
....................................................................................................................xxi
Chapter
1
Introduction
.........................................................................................1
1.1
Nature and Scope of Part 1
............................................................................1
1.2
Nature and Scope of Part II
...........................................................................3
1.3
The Role of aFacility Planner
.......................................................................5
1.4
Computer Programs
.......................................................................................5
Suggested Readings
...................................................................................................6
PART
1
Planning and Design
Chapter
2
Product Development
..........................................................................9
2.1
Market Research
............................................................................................9
.1
Market Potential
............................................................................10
.2
Collection of Data
.........................................................................11
.3
Survey Form
..................................................................................11
.4
Basic Steps in Market Research
....................................................12
1.5
Market Decision
............................................................................13
1.6
An Example of Market Research
..................................................13
2.2
Quality Function Deployment
.....................................................................17
2.3
Forecasting
..................................................................................................20
2.3.1
Error Measuring
............................................................................21
2.3.2
Forecasting Methods
.....................................................................21
2.3.2.1
Moving Average
..........................................................21
2.3.2.2
Weighted Moving Average
..........................................22
2.3.2.3
Exponential Smoothing
...............................................23
2.3.2.4
Curve Fitting
................................................................25
2.3.3
Demand Forecasting for a New Company
....................................28
2.4
Design
..........................................................................................................29
2.5
Design for Manufacture
...............................................................................31
2.5.1
Design Principles in DFM
............................................................31
2.5.2
Concurrent Engineering
................................................................33
2.5.3
Role of QFD, DFM, and
CE
in Facility Planning
........................33
2.6
Drawings
......................................................................................................34
2.6.1
Bill of Materials
............................................................................34
2.6.2
Additional Drawings
.....................................................................36
2.7
Economic Evaluation of Processes
..............................................................37
2.8
Computer-Aided Design
..............................................................................40
2.9
Computer Program Description
..................................................................43
2.9.1
Summary
.......................................................................................43
Problems..................................................................................................................44
Suggested Readings
.................................................................................................48
Chapters Automation
........................................................................................49
3.1
Sensing Methods
.........................................................................................49
3.2
Bar Codes
....................................................................................................51
3.2.1
Principles of Bar Code Technology
..............................................51
3.2.2
Bar Code Symbologies
..................................................................51
3.2.2.1 2
of
5
Code
..................................................................55
3.2.2.2
Interleaved
2
of
5
Code
................................................56
3.2.2.3
Code
3
of
9..................................................................57
3.2.3
Universal Product Code
................................................................58
3.2.4
Applications of the Bar Code
........................................................61
3.2.5
Equipment Used in Bar Code Applications
..................................62
3.2.5.1
Bar Code Readers
........................................................63
3.2.5.2
Bar Code Printers
........................................................65
3.2.5.3
Bar Code Verifiers/Analyzers
......................................66
3.3
Radio Frequency Identification System
.......................................................66
3.3.1
How Does The RFID System Work?
............................................67
3.3.2
Radio Data Communication
..........................................................68
3.4
Machine Vision
...........................................................................................68
3.4.1
Applications of Machine Vision
...................................................69
3.4.2
Typical Machine Vision Setup
......................................................70
3.4.3
Uses of Machine Vision in Manufacturing
...................................71
3.4.4
Two- and Three-Dimensional Machine Vision
.............................71
3.4.5
Machine Vision Processing
...........................................................72
3.5
Voice Input
...................................................................................................77
3.6
Programmable Logic Controllers
................................................................77
3.6.1
PLC in Material Handling
............................................................82
3.7
Numerically Controlled Machines
..............................................................86
3.7.1
Components of NC Machines
.......................................................86
3.7.1.1
Instructions
..................................................................86
3.7.1.2
Control Unit
.................................................................87
3.7.1.3
Machine Tool
...............................................................88
3.7.2
Machine System
............................................................................88
3.7.2.1
Conventional NC Machine
..........................................88
3.7.2.2
Direct Numerical Control
............................................89
3.7.2.3
Computer Numerical Control
......................................89
3.7.2.4
Modern DNC
...............................................................89
3.7.3
Advantages of NC Machines
........................................................90
3.7.4
Classification of NC Machines
.....................................................90
3.8
Industrial Robots
.........................................................................................93
3.8.1
Degrees of Freedom
......................................................................93
3.8.2
Classification of Robots
................................................................94
3.8.3
Robot Programming
......................................................................94
3.8.4
Selecting a Robot
..........................................................................94
3.8.5
Summary
.......................................................................................95
Problems
..................................................................................................................96
Suggested Readings
...............................................................................................101
Chapter
4
Production Charts and Systems
......................................................103
4.1
Production Charts
......................................................................................103
4.1.1
Symbols and Descriptions
...........................................................103
4.1.2
Assembly and Operation Process Charts
....................................104
4.1.3
Time Estimates
............................................................................106
4.1.4
Routing Sheet or Production Work Order
...................................107
4.1.5
Other Charts
................................................................................108
4.1.5.1
Left-Hand, Right-Hand Chart
...................................108
4.1.5.2
Gang Chart
................................................................109
4.1.5.3
Gantt Chart
................................................................110
4.1.5.4
Flow Process Chart
...................................................
HI
4.2
Production Systems
...................................................................................
Ill
4.2.1
Job Shop Production
...................................................................
Ill
4.2.2
Batch Production
.........................................................................113
4.2.3
Mass Production
..........................................................................114
4.2.4
Cellular and Flexible Manufacturing
..........................................114
4.3
Cell Formation in Group Technology
....................................................... 116
4.3.1
Solution Procedure
......................................................................117
4.3.1.1
Phase I
....................................................................... 117
4.3.1.2
Phase II
......................................................................119
4.3.1.3
Phase III: Further Group Evaluation with
Additional Objectives
................................................123
4.3.1.4
Phase III Procedure
...................................................123
4.3.2
Layout Considerations with Cellular Manufacturing
.................128
4.4
Labor Assignments
....................................................................................128
4.4.1
Labor Assignment in Production Lines
......................................129
4.4.1.1
Labor Planning
..........................................................132
4.4.2
Assembly Line Balancing
...........................................................132
4.4.2.1
Balancing Procedures
................................................133
4.4.3
Parallel Grouping of Stations
......................................................139
4.4.4
Computerized Assembly Line Programs
....................................141
4.4.4.1
Applicable Programs by Others
................................141
4.5
Computer Program Description
................................................................ 141
4.5.1
Assembly Line Balancing (in GW-BASIC)
................................142
4.5.1.1
Largest Candidate Rule
.............................................142
4.5.1.2
RPW Method
............................................................. 142
4.5.2
GT Computer Programs
..............................................................142
4.5.2.1
Group
.........................................................................143
4.5.2.2
Largroup
....................................................................144
4.6
Summary
...................................................................................................144
Problems................................................................................................................ 147
Suggested Readings
...............................................................................................152
Chapter
5
Requirements and Selection of Machines and Labor
.....................155
5.1
Machine Selection
.....................................................................................155
5.1.1
Make-or-Buy Analysis
................................................................155
5.1.2
Sources
ofinformation
...............................................................158
5.1.2.1
Books and Periodicals
...............................................158
5.1.2.2
Computer Databases
..................................................159
5.1.3
Production Arrangement
.............................................................160
5.1.4
Cost Consideration
......................................................................160
5.1.5
Available Capacity
......................................................................160
5.1.6
Required Capacity
.......................................................................162
5.1.7
Number of Machines Needed
.....................................................162
5.1.7.1
Extensions of Variations on Stage Analysis
..............164
5.1.7.2
System Decomposition
..............................................166
5.1.8
Machine Specifications
...............................................................169
5.1.9
Auxiliary Equipment
..................................................................171
5.2
Labor Requirement and Selection
.............................................................171
5.2.1
Job Evaluation
.............................................................................171
5.2.1.1
Sample Job Evaluation: Machine Shop Supervisor...
173
5.2.1.2
Sample Job Evaluation: Salary Determination
..........173
5.2.2
Standard Job Analysis
.................................................................174
5.2.3
Job Definition and Description
...................................................175
5.3
Machine Coupling
.....................................................................................177
5.3.1
Example of Machine Coupling
...................................................177
5.3.1.1
Alternative A
.............................................................177
5.3.1.2
Alternative
В
.............................................................178
5.3.1.3
Alternative
С
.............................................................178
5.3.1.4
Alternative
D
.............................................................180
5.4
Total Personnel Requirement
....................................................................181
5.5
Summary
...................................................................................................183
Problems
................................................................................................................183
Suggested Readings
...............................................................................................187
Chapter
6
Lean Manufacturing and Supply Chain
..........................................189
6.1
Lean Manufacturing
..................................................................................189
6.1.1
5S System
....................................................................................190
6.1.1.1
Sort
............................................................................190
6.1.1.2
Straighten
...................................................................191
6.1.1.3
Shine
..........................................................................193
6.1.1.4
Standardize
................................................................193
6.1.1.5
Sustain
.......................................................................193
6.1.2
Six Sigma
....................................................................................194
6.1.2.1
Define
........................................................................194
6.1.2.2
Measure
.....................................................................194
6.1.2.3
Analyze
......................................................................195
6.1.2.4
Improve
......................................................................197
6.1.2.5
Control
.......................................................................197
6.1.2.6
Replicate
....................................................................198
6.1.3
Kaizen Philosophy
......................................................................198
6.1.4
Andon
..........................................................................................199
6.1.5 Takt
Time
....................................................................................200
6.1.6
Single Minute Exchange of Die
..................................................201
6.1.7
Value Stream Mapping
................................................................202
6.1.8
Kanban
........................................................................................207
6.1.9
Total Production Maintenance
....................................................209
6.1.9.1
Available Time on Machine
......................................209
6.1.9.2
Machine Speed
..........................................................210
6.1.9.3
Increase Yield
............................................................210
6.1.10
Visual Management
....................................................................212
6.1.11
Multiskill Workers
......................................................................213
6.1.12
A Case Study in Lean
.................................................................214
6.1.13
Toyota Production System
...........................................................242
6.2
Supply Chain
.............................................................................................242
6.2.1
Distribution Problem
...................................................................243
6.2.2
Aggregate Planning Model
.........................................................244
6.2.2.1
Formulation and Solution
..........................................245
6.2.3
Just-in-Time Production/Pickups
................................................247
6.2.3.1
Linear Heuristic Programming Formulation
............248
6.3
Summary
...................................................................................................251
Problems
................................................................................................................251
Chapter
7
Building, Organization, Communications,
and Selected Support Requirements
...............................................255
7.1
Building
.....................................................................................................255
7.1.1
Conventional Building Characteristics
.......................................255
7.1.1.1
Structure
....................................................................256
7.1.1.2
Walls
..........................................................................256
7.1.1.3
Floor
..........................................................................256
7.1.1.4
Roof
...........................................................................257
7.1.1.5
Interior
.......................................................................257
7.1.2
Prefabricated Buildings
...............................................................258
7.2
Organization
..............................................................................................258
7.2.1
Organizational Concepts
.............................................................258
7.2.2
Organization Charts
....................................................................259
7.2.3
Organizational Structures
...........................................................259
7.2.3.1
Line Organization
......................................................259
7.2.3.2
Staff-Line Organization
............................................260
7.2.3.3
Product Organization
................................................261
7.2.3.4
Matrix Organization
..................................................262
7.2.4
Selection of Organization Structure
............................................262
7.3
Communications
........................................................................................263
7.3.1
Written Messages
........................................................................263
7.3.2
Spoken Messages
........................................................................263
7.3.3
Methods of Presentation
.............................................................263
7.3.4
Documentation
............................................................................264
7.4
Support Facilities and Requirements
.........................................................265
7.4.1
Shop Offices
................................................................................265
7.4.2
Inspection
....................................................................................265
7.4.3
Maintenance
................................................................................265
7.4.4
Toolroom
.....................................................................................267
7.4.5
Tool Crib
.....................................................................................267
7.4.6
Lockers/Changing Area
..............................................................268
7.4.7
Lavatories
....................................................................................269
7.4.8
Janitorial and Custodial Services
................................................270
7.4.9
Eating Area
.................................................................................271
7.4.10
Security Force
.............................................................................273
7.4.11
Parking Lot
.................................................................................273
7.4.12
Medical Facilities
........................................................................274
7.4.13
Noise Exposure
...........................................................................275
7.5
Summary
...................................................................................................275
Problems
................................................................................................................276
Suggested Readings
...............................................................................................277
Chapter
8
Material Handling
Principles and Equipment Description
..........................................279
8.1
Definition of Material Handling
................................................................279
8.2
Objectives of Material Handling
...............................................................280
8.3
Material-Handling Equipment Types
........................................................280
8.3.1
Conveyors
....................................................................................280
8.3.1.1
Advantages of Conveyors
..........................................281
8.3.1.2
Disadvantages of Conveyors
......................................281
8.3.2
Cranes and Hoists
........................................................................281
8.3.2.1
Advantages of Cranes and Hoists
..............................283
8.3.2.2
Disadvantages of Cranes and Hoists
.........................283
8.3.3
Trucks
..........................................................................................283
8.3.3.1
Advantages of Trucks
................................................283
8.3.3.2
Disadvantages of Trucks
...........................................284
8.4
Degrees of Mechanization
.........................................................................285
8.5
The Unit Load Concept
.............................................................................286
8.6
Principles of Material Handling
................................................................286
8.6.1
Compatibility of the Principles
...................................................288
8.6.2
Difficulties in Applications of the Principles
..............................288
8.7
Material-Handling Cost
.............................................................................289
8.8
Relationship between Material Handling and Plant Layout
......................289
8.9
MHS
Design
..............................................................................................290
8.10
Dilemmaofan
Analyzer
...........................................................................290
8.11
Spécifications
of the Design
......................................................................291
8.12
Analyzing an Existing
MHS
.....................................................................292
8.13
Productivity Ratios
....................................................................................295
8.13.1
Material-Handling/Labor (MHL) Ratio
.....................................295
8.13.2
Handling Equipment Utilization
(HEU)
Ratio
...........................295
8.13.3
Storage Space Utilization
(SSU)
Ratio
.......................................295
8.13.4
Aisle Space Percentage (ASP)
.....................................................296
8.13.5
Movement Operation (MO) Ratio
...............................................296
8.13.6
Manufacturing Cycle Efficiency (MCE)
.....................................296
8.13.7
Damaged Loads (DL) Ratio
........................................................296
8.13.8
Energy Ratio
(ER).......................................................................296
8.13.9
Equipment Used for Material Handling
......................................297
8.13.10
Equipment Types
.........................................................................297
8.13.10.1
Equipment Description
..............................................298
8.13.10.2
Accessories
................................................................323
8.13.10.3
Optical Code, or Bar Code, Reader
...........................325
8.14
Summary
...................................................................................................326
Problems
................................................................................................................327
Suggested Reading
.................................................................................................328
Chapter
9
Material Handling
Equipment Selection
.......................................................................329
9.1
Basics of Equipment Selection
..................................................................329
9.1.1
Work Volume Analysis
...............................................................333
9.2
Robots in Material Handling
.....................................................................342
9.2.1
Robot
Grippers
for Loading and Unloading Operations
............342
9.2.2
Calculation of Cycle Times
.........................................................342
9.2.3
Sequential Loading
.....................................................................343
9.3
AGVs in Material Handling
......................................................................349
9.3.1
Introducing an AGV in the Manufacturing Plant
.......................351
9.4
Simulation of an AGV Material-Handling System
...................................353
9.4.1
Explanation of Simulation Logic
................................................359
9.4.1.1
Line I
.........................................................................359
9.4.1.2
Line
2.........................................................................359
9.4.1.3
Line
3.........................................................................359
9.4.1.4
Lines
4
and
5.............................................................360
9.4.1.5
Lines
6
and
7.............................................................361
9.4.1.6
Line
8.........................................................................361
9.4.1.7
Line
9.........................................................................361
9.4.1.8
Line
10.......................................................................361
9.4.1.8
Line
11.......................................................................361
9.4.1.9
Line
12.......................................................................361
9.4.1.10
Line
13.......................................................................361
9.4.1.11
Line
14.......................................................................361
9.4.1.12
Line
15.......................................................................362
9.4.1.13
Line
16.......................................................................362
9.4.1.14
Line
17.......................................................................362
9.4.1.15
Line
18.......................................................................362
9.5
Summary
...................................................................................................363
Problems
................................................................................................................363
Suggested Readings
...............................................................................................367
Chapter
10
Material Handling
Flow Lines, Grouping, and Packaging
...........................................369
10.1
Flow Pattern in Assembly Lines
...............................................................369
10.1.1
Serial and Modular Conveyor Systems
.......................................369
10.1.2
Banking
.......................................................................................371
10.1.2.1
Machine Layouts
.......................................................374
10.1.3
Queuing Models
..........................................................................383
10.1.4
Closed-Loop Conveyor Systems
.................................................389
10.1.5
Automated Controls and Transfers
.............................................393
10.1.5.1
Automated Transfer Machines
..................................395
10.1.5.2
Monorails
...................................................................395
10.1.6
Horizontal and Vertical Flow
......................................................395
10.1.7
Material Flow in Cellular and Job Shops
....................................397
10.2
Machine Grouping in Cellular Manufacturingwith Reduction of
Material Handling as the Objective
...........................................................397
10.2.1
Economic Analysis
.....................................................................404
10.2.2
Evaluation Procedure
..................................................................409
10.2.2.1
Solution with a Single Cell
........................................409
10.2.2.2
Solution with
Ρ
= 0.1-0.6..........................................410
10.3
Machine Placement in Job Shop or Cellular Manufacturing
....................413
10.3.1
Phase I: Initial Solution
...............................................................413
10.3.1.1
Facility or Machine Chain
.........................................413
10.3.1.2
Location Chain
..........................................................414
10.3.2
Phase II: Improvement Routine
..................................................414
10.3.2.1
Initial Solution
...........................................................414
10.4
Packaging
..................................................................................................420
10.4.1
Functions
.....................................................................................420
10.4.2
Protection
....................................................................................423
10.4.3
Design and Material Considerations
...........................................423
10.4.3.1
Glass
..........................................................................423
10.4.3.2
Metal
..........................................................................424
10.4.3.3
Paper Products
...........................................................424
10.4.3.4
Cartons
......................................................................424
10.4.3.5
Bags
...........................................................................425
10.4.3.6
Wood
..........................................................................426
10.4.4
Consolidation and Palletizing
.....................................................426
10.4.4.1
Shrink/Stretch Film
...................................................427
10.4.4.2
Strapping
....................................................................427
10.4.4.3
Labeling
.....................................................................428
10.4.4.4
Final Step
...................................................................428
10.4.5
Packaging
Equipment
.................................................................428
10.4.5.1
Automatic
Adhesive Sealers
......................................428
10.4.5.2
Automatic Tape Sealers
.............................................428
10.4.5.3
Stitchers
.....................................................................428
10.4.5.4
Staplers
......................................................................429
10.4.5.5
Strappers
....................................................................429
10.4.5.6
Wrappers
....................................................................429
10.4.5.7
Palletizers
..................................................................429
10.5
Reducing Packaging Costs
........................................................................430
10.5.1
Design
.........................................................................................430
10.5.2
Material
.......................................................................................431
10.5.3
Production
...................................................................................431
10.6
Designing a Packaging Area
.....................................................................431
10.7
Computer Program Description
................................................................432
10.7.1
Machine Grouping to Reduce Material Handling
......................432
10.7.2
Machine Placement in Flexible Manufacturing
..........................433
10.8
Summary
...................................................................................................433
Problems
................................................................................................................434
Suggested Readings
...............................................................................................440
Chapter
11
Storage and Warehousing
................................................................441
11.1
Warehouse Ownership
...............................................................................441
11.2
Storage/Warehouse Location
.....................................................................442
11.3
Building
.....................................................................................................442
11.3.1
Building and Layout Considerations
...........................................443
11.3.2
Space Determination
...................................................................444
11.4
Material Requirement Planning
................................................................446
11.4.1
Data for MRP
..............................................................................447
11.4.2
MRP Procedure
...........................................................................448
11.4.3
Order Quantity
............................................................................450
11.4.4
Part Period Balancing (PPB)
.......................................................451
11.4.5
Safety Stock Considerations
.......................................................453
11.4.6
Lead Time Considerations
..........................................................453
11.5
Storage/Warehouse Functions
...................................................................454
11.6
Storage and Warehouse Operations
...........................................................455
11.6.1
Storage Policies
...........................................................................455
11.6.2
Order Picking Policies
................................................................458
11.7
Accessories
................................................................................................461
11.7.1
Storage Racks
..............................................................................462
11.7.1.1
Selective Pallet Racks
................................................462
11.7.1.2
Movable-Shelf Racks
.................................................463
11.7.1.3
Drive-In and Drive-Through Racks
...........................463
11.7.1.4
Cantilever Racks
........................................................464
11.7.1.5
Stacker Crane Racks
..................................................464
11.7.1.6
Portable Racks
...........................................................465
11.7.1.7
Rack Buildings
..........................................................465
11.7.1.8
Fire Prevention
..........................................................465
11.8
Stock Location
...........................................................................................466
11.9
Automated Storage and Retrieval
..............................................................467
11.9.1
Design of AS/R Systems
.............................................................468
11.9.2
Cost Estimate
..............................................................................471
11.9.3
Order Picking in an AS/R System
..............................................471
11.10
Loading Docks
...........................................................................................473
11.11
Dock Doors
................................................................................................477
11.12
Computer Program Description
.................................................................479
11.12.1
Material Requirement Planning
.................................................479
11.12.1.1
Option
1
(Enter the BOM File)
..................................479
11.12.1.2
Option
2
(Process the BOM File)
..............................481
11.12.1.3
Option
3
(Load the BOM File)
..................................483
11.12.1.4
Option
4
(Save the BOM File)
...................................484
11.12.1.5
Option
5
(Exit)
..........................................................484
11.12.2
Caveats
........................................................................................484
11.13
Summary
...................................................................................................484
Problems
................................................................................................................486
Suggested Readings
...............................................................................................490
Chapter
12
Plant and Office Layout
Conventional Approach
..................................................................493
12.1
Procedure
...................................................................................................493
12.2
Detailed Layout
.........................................................................................508
12.3
Materials Used in Plant Layout Illustrations
.............................................514
12.4
Developing and Analyzing Plant Layouts
.................................................515
12.5
Presenting the Layout
................................................................................517
12.6
Office Layout
.............................................................................................519
12.7
Recent Trends in Office Layout
.................................................................525
12.7.1
Modular Workstation Approach
.................................................526
12.7.2
Cluster Workstation Approach
....................................................526
12.7.3
Office Landscaping Approach
....................................................527
12.8
Plot Planning
.............................................................................................528
12.9
Computer Program Description
................................................................529
12.9.1
Computer Layout Design II
.........................................................529
12.10
Summary
...................................................................................................539
Problems
................................................................................................................540
Suggested Readings
...............................................................................................543
Chapter
13
Computer-Aided Plant Layout
.........................................................545
13.1
Characteristics of the Problems
.................................................................545
13.2
Data Requirements
....................................................................................546
13.3
Approaches and Types of Procedures
.......................................................546
13.4
Mathematical Programming
.....................................................................547
13.5
Heuristics
...................................................................................................549
13.5.1
Computerized Relationship Layout Planning
.............................550
13.5.2
Plant Layout Analysis and Evaluation Technique
.......................552
13.5.2.1
Method A
...................................................................553
13.5.2.2
Method
В
...................................................................553
13.5.2.3 Methode...................................................................553
13.5.3
Modular Allocation Technique
...................................................555
13.5.4
Computerized Relative Allocation of Facilities Technique
........556
13.6
Probabilistic Approaches
...........................................................................559
13.6.1
Random Selection
.......................................................................559
13.6.2
Biased Sampling
.........................................................................559
13.6.3
Simulation
...................................................................................560
13.7
Recent Plant Layout Software
...................................................................560
13.7.1
CATIA Plant Layout
1................................................................560
13.7.1.1
Features
.....................................................................561
13.7.1.2
Key Customer Benefits
..............................................561
13.7.2
PlantWise
....................................................................................563
13.7.3
CADWorx Plant and Plant Professional by COADE,
Inc
...........563
13.7.3.1
2D and
3D
Piping
......................................................564
13.7.3.2
Structural Steel
..........................................................564
13.7.3.3
Equipment
..................................................................564
13.7.3.4
Ducting/Cable Trays
..................................................564
13.7.3.5
Automatic Isometrics
.................................................564
13.7.3.6
Piping Specifications
.................................................564
13.7.3.7
Bills of Material
.........................................................565
13.7.3.8
Export to External Database
.....................................565
13.7.3.9
Bidirectional Links to Stress Analysis
......................565
13.7.3.10
Automated Stress Isometrics
.....................................565
13.7.3.11
Live Database Links
..................................................565
13.7.3.12
CADWorx Equipment
...............................................565
13.7.3.13
Personal ISOGEN
......................................................566
13.7.3.14
Model Review and Walkthrough
...............................566
13.7.4
Flow Planner
...............................................................................566
13.7.5
FactoryFLOW
.............................................................................566
13.7.5.1
The Shortest Distance Between Two Points
..............566
13.7.5.2
The Competitive Advantage
......................................567
13.7.5.3
FactoryCAD
..............................................................568
13.7.5.4
Major Capabilities
.....................................................569
13.8
Summary
...................................................................................................570
Problems
................................................................................................................570
Suggested Readings
...............................................................................................572
Chapter
14
Simultaneous Development of Plant Layout
and Material Handling
....................................................................575
14.1
An Algorithm for MH Equipment Selection
.............................................576
14.1.1
Phase I: Construction of an Initial Feasible Solution
..................578
14.1.1.1
Calculating the Rectilinear Distances
between the Departments
..........................................578
14.1.1.2
Determining a Conveyor System for the Entire
MHTask
....................................................................578
14.1.1.3
Designing a Truck System for the Entire MH
Task
............................................................................578
14.1.2
Phase II: Improvement Procedure
...............................................582
14.2
Illustrative Example
1................................................................................584
14.2.1
Initial Data Preparation
...............................................................584
14.2.2
Application of the Heuristic Procedure
......................................589
14.2.2.1
Phase I: Construction of an Initial Feasible
Solution
......................................................................589
14.2.2.2
Phase II: Improvement Procedure
............................593
14.3
An Iterative Process for Layout and Optimum MH Development
............597
14.4
Illustrative Example
2................................................................................601
14.5
Comparison of the Analytical and Heuristic Approaches
forMH System Development
....................................................................604
14.6
Computer Program Description
................................................................605
14.7
Summary
...................................................................................................605
Problems
................................................................................................................605
Suggested Readings
...............................................................................................609
Chapter
15
Plant Site Selection and Service (Support) Considerations
.............611
15.1
Plant Site Selection
....................................................................................611
15.1.1
Factors Influencing Site Selection
...............................................612
Transportation Facilities
............................................612
Adequate Labor Supply
.............................................613
Availability of Land
...................................................613
Nearness to Markets
..................................................613
Suitable Utilities
........................................................613
Proximity of Raw Materials
......................................614
Geographical and Weather Considerations
...............614
1.1.8
Taxes and Legal Considerations
................................614
1.1.9
Community Considerations
.......................................615
1.1.10
National Security
.......................................................615
1.1.11
Proximity
toan
Existing Plant
..................................615
15.1.2
Procedures for Site Selection
......................................................615
15.1.3
Industrial Parks
...........................................................................617
15.2
Utilities Specifications
...............................................................................617
15.2.1
Water
...........................................................................................617
15.2.2
Electricity
....................................................................................618
15.2.3
Lighting
.......................................................................................618
15.2.3.1
Development of the Light Arrangement in the
Work Area
.................................................................619
15.2.3.2
Working Environment
...............................................620
15.
.1.1
15.
.1.2
15.
.1.3
15.
1.1.4
15.
1.1.5
15.
.1.6
15.
1.1.7
15.
15.
15.
15.
15.2.3.3
Ceiling and Wall Reflectivity
....................................620
15.2.3.4
Volume of Space Between Light Fixtures
and Work Area
...........................................................621
15.2.3.5
Minimum Illumination Level (MIL)
.........................622
15.2.4
Compressed Air
..........................................................................625
15.2.5
Process Waste Products
..............................................................625
15.2.6
Steam
...........................................................................................625
15.2.7
Ventilation
...................................................................................625
15.2.8
Waste Disposal and Treatment
....................................................626
15.2.9
Air-Conditioning and Heating
....................................................626
15.2.10
Telephone Services
......................................................................633
15.2.11
Conservation Measures
...............................................................633
15.3
Insurance
...................................................................................................638
15.3.1
Types of Insurance
......................................................................639
15.3.2
Commercial Lines
.......................................................................639
15.3.2.1
Essential Coverages
...................................................639
15.3
Safety
.........................................................................................................642
15.3.1
When to Plan
...............................................................................643
15.3.2
Regulation
...................................................................................643
15.3.3
Responsibility within a Plant
......................................................644
15.3.4
Safety Program
...........................................................................644
15.3.5
Americans with Disabilities Act of
1990....................................647
15.3.6
Assisting Individuals in Wheelchairs
.........................................648
15.3.6.1
Flooring
.....................................................................648
15.3.6.2
Parking
......................................................................648
15.3.6.3
Accessible Paths
........................................................649
15.3.6.4
Workstation
................................................................649
15.3.7
Assisting Visually and Hearing Impaired People
.......................649
15.3.7.1
Headroom
..................................................................649
15.3.7.2
Objects Protruding from Walls
.................................649
15.3.8
Other Considerations
...................................................................650
15.3.8.1
Emergencies
...............................................................650
15.3.8.2
Lavatories
..................................................................650
15.3.8.3
Toilet Stalls, Urinals, and Drinking Fountains
.........650
15.4
Taxes
..........................................................................................................650
15.4.1
Federal Income Tax
.....................................................................651
15.4.2
Social Security Act
.....................................................................651
15.4.3
Unemployment Compensation
....................................................653
15.4.4
Sales Taxes
..................................................................................654
15.4.5
Property Taxes
............................................................................654
15.4.5
Comments
...................................................................................654
15.5
Financial Statements
.................................................................................654
15.6
Computer Program Description
................................................................656
15.7
Summary
...................................................................................................662
Problems
................................................................................................................663
Suggested Readings
...............................................................................................665
Chapter
16
Computer-Integrated Manufacturing System
..................................667
16.1
Systems and Files
......................................................................................667
16.2
Components of CIMS
................................................................................669
16.2.1
Computer-Aided Design
..............................................................669
16.2.2
Group Technology
.......................................................................670
16.2.3
Computer-Aided Manufacturing
.................................................670
16.2.4
Robots
.........................................................................................671
16.2.5
Material Handling
.......................................................................671
16.2.6
Computer Systems
.......................................................................672
16.2.7
Control Software
.........................................................................673
16.3
Benefits and Deficiencies of CIMS
...........................................................675
16.4
Planning for CIMS
....................................................................................675
16.5
System Providers
.......................................................................................677
Problems
................................................................................................................678
Suggested Readings
...............................................................................................679
PART
2
Facility Location
Chapter
17
Basic Facility Location Problems
...................................................683
17.1
Single-Facility Placement Problem
...........................................................683
17.1.1
Solution Procedure
......................................................................683
17.1.2
Application to the Sample Problem
............................................684
17.2
Multiple-Facility Placement Problem
........................................................684
17.3
Brute Force Approach
...............................................................................685
17.4
Heuristic Method for Problems Involving Facilities
with Unlimited Capacities
.........................................................................688
17.4.1
Application
..................................................................................688
17.4.2
Validity
........................................................................................692
17.5
Other Methods
...........................................................................................692
17.6
Computer Program Description
................................................................693
17.6.1
Heuristic Method
........................................................................693
17.7
Summary
...................................................................................................694
Problems
................................................................................................................694
Suggested Readings
...............................................................................................696
Chapter
18
Location Analysis with Fixed Costs
...............................................697
18.1
Heuristic Method for Solving Problems with Fixed Costs
........................698
18.2
Application
................................................................................................700
18.2.1
Solution
.......................................................................................701
18.3
Unassignable Location
..............................................................................705
18.4
Computer Program Description
................................................................709
18.4.1
Purpose
.......................................................................................709
18.4.2
Program Description
...................................................................710
18.5
Summary
...................................................................................................712
Problems................................................................................................................713
Suggested Readings
...............................................................................................716
Chapter
19
Continuous Facility Location
..........................................................717
19.1
Single-Facility Locations
..........................................................................718
19.1.1
Rectilinear Distance Cost
...........................................................718
19.1.2
Single-Facility Location
—
Quadratic Cost
...............................720
19.1.3
Euclidean Distance Cost
.............................................................721
19.2
Multiple Facilities
......................................................................................723
19.2.1
Multiple Facilities of Different Types
.........................................723
19.2.1.1
Rectilinear Cost
.........................................................723
19.2.1.2
Quadratic and Euclidean Distance Cost
....................727
19.3
Multiple Facilities of the Same Type
.........................................................727
19.4
Computer Program Description
................................................................730
19.4.1
Single-Facility Problems
.............................................................730
19.4.1.1
Rectilinear Distance Cost Method
............................730
19.4.1.2
Quadratic Cost Model
...............................................731
19.4.2
Multiple Facilities of the Same Type Problems
..........................731
19.5
Summary
...................................................................................................731
Problems
................................................................................................................731
Suggested Readings
...............................................................................................734
Appendix A: Engineering Economy Formulas
.................................................735
Appendix B: Quality Assurance Manual, Spring Controls,
Inc
........................737
Appendix C: Queuing Results
...........................................................................745
Appendix D: Mathematical Formulation for Material Equipment Selection...
747
Appendix E: Samples of Americans with Disabilities
Act of
1990
Checklists
.................................................................749
Appendix F: Case Studies
..................................................................................759
Appendix G: Manufacturing Facilities: Computer Programs
...........................769
Index
......................................................................................................................773
|
| any_adam_object | 1 |
| author | Sule, Dileep R. |
| author_facet | Sule, Dileep R. |
| author_role | aut |
| author_sort | Sule, Dileep R. |
| author_variant | d r s dr drs |
| building | Verbundindex |
| bvnumber | BV035064784 |
| callnumber-first | T - Technology |
| callnumber-label | TS177 |
| callnumber-raw | TS177 |
| callnumber-search | TS177 |
| callnumber-sort | TS 3177 |
| callnumber-subject | TS - Manufactures |
| classification_rvk | QP 550 |
| ctrlnum | (OCoLC)635922659 (DE-599)HBZHT015814352 |
| dewey-full | 658.2 |
| dewey-hundreds | 600 - Technology (Applied sciences) |
| dewey-ones | 658 - General management |
| dewey-raw | 658.2 |
| dewey-search | 658.2 |
| dewey-sort | 3658.2 |
| dewey-tens | 650 - Management and auxiliary services |
| discipline | Wirtschaftswissenschaften |
| edition | 3. ed. |
| format | Book |
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| id | DE-604.BV035064784 |
| illustrated | Illustrated |
| indexdate | 2024-12-23T21:12:49Z |
| institution | BVB |
| isbn | 9781420044225 |
| language | English |
| lccn | 2008017803 |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-016733255 |
| oclc_num | 635922659 |
| open_access_boolean | |
| owner | DE-703 |
| owner_facet | DE-703 |
| physical | 799 S. Ill., graph. Darst. |
| publishDate | 2008 |
| publishDateSearch | 2008 |
| publishDateSort | 2008 |
| publisher | CRC Press |
| record_format | marc |
| spellingShingle | Sule, Dileep R. Manufacturing facilities location, planning, and design Factories Design and construction Factories Location Fertigungsanlage (DE-588)4140388-5 gnd Diskette (DE-588)4122115-1 gnd Anlagenwirtschaft (DE-588)4198888-7 gnd Fabrikplanung (DE-588)4134388-8 gnd Planung (DE-588)4046235-3 gnd |
| subject_GND | (DE-588)4140388-5 (DE-588)4122115-1 (DE-588)4198888-7 (DE-588)4134388-8 (DE-588)4046235-3 |
| title | Manufacturing facilities location, planning, and design |
| title_auth | Manufacturing facilities location, planning, and design |
| title_exact_search | Manufacturing facilities location, planning, and design |
| title_full | Manufacturing facilities location, planning, and design Dileep R. Sule |
| title_fullStr | Manufacturing facilities location, planning, and design Dileep R. Sule |
| title_full_unstemmed | Manufacturing facilities location, planning, and design Dileep R. Sule |
| title_short | Manufacturing facilities |
| title_sort | manufacturing facilities location planning and design |
| title_sub | location, planning, and design |
| topic | Factories Design and construction Factories Location Fertigungsanlage (DE-588)4140388-5 gnd Diskette (DE-588)4122115-1 gnd Anlagenwirtschaft (DE-588)4198888-7 gnd Fabrikplanung (DE-588)4134388-8 gnd Planung (DE-588)4046235-3 gnd |
| topic_facet | Factories Design and construction Factories Location Fertigungsanlage Diskette Anlagenwirtschaft Fabrikplanung Planung |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=016733255&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
| work_keys_str_mv | AT suledileepr manufacturingfacilitieslocationplanninganddesign |