Facilities Planning, 4th Edition

Part One DEFINING REQUIREMENTS 1

Chapter One INTRODUCTION 3

1.1 Facilities Planning Defined 3

1.2 Significance of Facilities Planning 9

1.3 Objectives of Facilities Planning 12

1.4 Facilities Planning Process 13

1.5 Strategic Facilities Planning 18

1.6 Developing Facilities Planning Strategies 21

1.7 Examples of Inadequate Planning 24

1.8 Summary 26

References 27

Problems 28

Chapter Two PRODUCT, PROCESS, AND SCHEDULE DESIGN 30

2.1 Introduction 30

2.2 Product Design 32

2.3 Process Design 36

2.4 Schedule Design 47

2.5 Facilities Design 63

2.6 Summary 70

References 72

Problems 74

Chapter Three FLOW SYSTEMS, ACTIVITY RELATIONSHIPS, AND SPACE REQUIREMENTS 83

3.1 Introduction 83

3.2 Flow Systems 84

3.3 Material Flow System 88

3.4 Departmental Planning 97

3.5 Activity Relationships 113

3.6 Space Requirements 119

3.7 Summary 129

References 129

Problems 131

Chapter Four PERSONNEL REQUIREMENTS 137

4.1 Introduction 137

4.2 The Employee–Facility Interface 138

4.3 Restrooms 146

4.4 Food Services 151

4.5 Health Services 156

4.6 Barrier-Free Compliance 157

4.7 Office Facility Planning 160

4.8 Summary 170

References 170

Problems 171

Part Two DEVELOPING ALTERNATIVES: CONCEPTS AND TECHNIQUES 173

Chapter Five MATERIAL HANDLING 175

5.1 Introduction 175

5.2 Scope and Definitions of Material Handling 176

5.3 Material Handling Principles 179

5.4 Designing Material Handling Systems 181

5.5 Unit Load Design 186

5.6 Material Handling Equipment 204

5.7 Estimating Material Handling Costs 209

5.8 Safety Considerations 210

5.9 Summary 212

References 212

Problems 213

Appendix 5B Material Handling Equipment 215

Chapter Six LAYOUT PLANNING MODELS AND DESIGN ALGORITHMS 292

6.1 Introduction 292

6.2 Basic Layout Types 294

6.3 Layout Procedures 296

6.4 Algorithmic Approaches 302

6.5 Department Shapes and Mail Aisles 342

6.6 Simulated Annealing and Genetic Algorithms 344

6.7 Multi-Floor Facility Layout 351

6.8 Commercial Facility Layout Packages 354

6.9 The Impact of Change 355

6.10 Developing Layout Alternatives 362

6.11 Summary 363

References 366

Problems 369

Part Three FACILITY DESIGN FOR VARIOUS FACILITIES FUNCTIONS 383

Chapter Seven WAREHOUSE OPERATIONS 385

7.1 Introduction 385

7.2 Missions of a Warehouse 387

7.3 Functions in the Warehouse 389

7.4 Receiving and Shipping Operations 391

7.5 Dock Locations 414

7.6 Storage Operations 415

7.7 Order Picking Operations 432

7.8 Summary 443

References 443

Problems 444

Chapter Eight MANUFACTURING SYSTEMS 448

8.1 Introduction 448

8.2 Fixed Automation Systems 451

8.3 Flexible Manufacturing Systems 453

8.4 Single-Stage Multimachine Systems 456

8.5 Reduction in Work-in-Process 458

8.6 Just-in-Time Manufacturing 459

8.7 Facilities Planning Trends 467

8.8 Summary 468

References 469

Problems 470

Chapter Nine FACILITIES SYSTEMS 473

9.1 Introduction 473

9.2 Structural System Performance 474

9.3 Enclosure Systems 477

9.4 Atmospheric Systems 481

9.5 Electrical and Lighting Systems 490

9.6 Life Safety Systems 500

9.7 Sanitation Systems 505

9.8 Building Automation Systems 508

9.9 Facilities Maintenance Management Systems 510

9.10 Summary 510

References 511

Problems 511

Part Four DEVELOPING ALTERNATIVES: QUANTITATIVE APPROACHES 515

Chapter Ten QUANTITATIVE FACILITIES PLANNING MODELS 517

10.1 Introduction 517

10.2 Facility Location Models 518

10.3 Special Facility Layout Models 569

10.4 Machine Layout Models 577

10.5 Conventional Storage Models 580

10.6 Automated Storage and Retrieval Systems 608

10.7 Order Picking Systems 627

10.8 Fixed-Path Material Handling Models 642

10.9 Waiting Line Models 671

10.10 Simulation Models 701

10.11 Summary 705

References 705

Problems 709

Part Five EVALUATING, SELECTING, PREPARING, PRESENTING, IMPLEMENTING, AND MAINTAINING 743

Chapter Eleven EVALUATING AND SELECTING THE FACILITIES PLAN 745

11.1 Introduction 745

11.2 Evaluating Facilities Plans 748

11.3 Selecting the Facilities Plan 802

11.4 Summary 803

References 803

Problems 804

Chapter Twelve PREPARING, PRESENTING, IMPLEMENTING, AND MAINTAINING THE FACILITIES PLAN 807

12.1 Introduction 807

12.2 Preparing the Facilities Plan 807

12.3 Presenting the Facilities Plan 831

12.4 Implementing the Facilities Plan 834

12.5 Maintaining the Facilities Plan 836

12.6 Summary 839

References 839

Problems 840

INDEX 841