Manufacturing Facilities Design and Material Handling

by Meyers, Fred E.; Stephens, Matthew P.

• ISBN13: 9780136748212
• ISBN10: 013674821X
• Edition: 2nd
• Format: Hardcover
• Copyright: 2000-01-01
• Publisher: Pearson College Div

Summary

For Sophomore/Junior-level courses in Plant and Facilities Planning and Manufacturing Systems and Procedures. This project-oriented facilities design and material handling textbook explores the techniques and procedures for developing an efficient facility layout, and introduces some of the state-of-the-art tools involved, such as computer simulation. A how-to, systematic, and methodical approach leads students through the collection, analysis and development of information to produce a quality functional plant layout.

Table of Contents

CHAPTER 1 Introduction to Manufacturing Facilities Design and Material Handling	1	(17)
THE IMPORTANCE OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING	1	(3)
LEAN THINKING AND LEAN MANUFACTURING	4	(1)
THE GOALS OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING	4	(5)
THE MANUFACTURING FACILITIES DESIGN PROCEDURE	9	(2)
TYPES AND SOURCES OF MANUFACTURING FACILITIES DESIGN PROJECTS	11	(1)
COMPUTERS AND SIMULATION IN MANUFACTURING FACILITIES DESIGN	12	(2)
ISO 9000 and Facilities Planning	13	(1)
GLOSSARY OF MAJOR TERMS	14	(2)
QUESTIONS	16	(2)
CHAPTER 2 Sources of Information for Manufacturing Facilities Design	18	(16)
THE MARKETING DEPARTMENT	19	(2)
THE PRODUCT DESIGN DEPARTMENT	21	(7)
MANAGEMENT POLICY INFORMATION	28	(4)
Inventory Policy	28	(1)
Lean Thinking and Muda as a Part of Management Policy	28	(1)
Investment Policy	29	(1)
Startup Schedule	29	(1)
Make or Buy Decisions	30	(1)
Organizational Relationships	30	(1)
Feasibility Studies	31	(1)
CONCLUSION	32	(1)
QUESTIONS	33	(1)
CHAPTER 3 Time Study	34	(42)
WHAT IS A TIME STANDARD?	34	(3)
IMPORTANCE AND USES OF TIME STUDY	37	(11)
1. How Many Machines Do We Need?	38	(1)
2. How Many People Should We Hire?	39	(2)
3. How Much Will Our Product Cost?	41	(2)
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	(1)
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	(1)
6. How Do We Measure Productivity?	44	(2)
7. How Can We Pay Our People for Outstanding Performance?	46	(1)
8. How Can We Select the Best Method or Evaluate Cost Reduction Ideas?	46	(2)
9. How Do You Evaluate New Equipment Purchases to Justify Their Expense?	48	(1)
10. How Do We Develop a Personnel Budget?	49
TECHNIQUES OF TIME STUDY	48	(17)
Predetermined Time Standards Systems	49	(3)
Stopwatch Time Study	52	(1)
Time Study Procedure and the Step-by-Step Form	52	(5)
Principles of Elemental Breakdown	57	(4)
Rating, Leveling, and Normalizing	61	(4)
ALLOWANCES	65	(9)
Types of Allowances	65	(3)
Methods of Applying Allowances	68	(3)
Work Sampling	71	(1)
Standard Data	72	(1)
Expert Opinion Time Standards and Historical Data	72	(2)
TIME STANDARDS FOR MANUFACTURING FACILITIES DESIGN	74	(1)
QUESTIONS	75	(1)
CHAPTER 4 Process Design	76	(30)
FABRICATION: MAKING THE INDIVIDUAL PARTS	77	(5)
Route Sheets	77	(3)
The Number of Machines Needed	80	(2)
WORK CELL LOAD CHART	82	(4)
Step-by-Step Procedure for Preparing a Work Cell Load Chart	86	(1)
ASSEMBLY AND PACKOUT PROCESS ANALYSIS	86	(8)
The Assembly Chart	87	(1)
Time Standards Are Required for Every Task	87	(1)
Plant Rate and Conveyor Speed	88	(1)
Paint Conveyor Speed	88	(2)
Assembly Line Balancing	90	(4)
STEP-BY-STEP PROCEDURE FOR COMPLETING THE ASSEMBLY LINE BALANCING FORM	94	(6)
CALCULATING THE EFFICIENCY OF THE ASSEMBLY LINE	100	(4)
Use of Computer Simulation	101	(3)
LAYOUT ORIENTATION	104	(1)
QUESTIONS	104	(2)
CHAPTER 5 Flow Analysis Techniques	106	(31)
FABRICATION OF INDIVIDUAL PARTS	109	(12)
String Diagram	110	(2)
Multi-Column Process Chart	112	(1)
From-To Chart	113	(4)
Process Chart	117	(1)
Step-by-Step Description for the Process Chart	117	(4)
TOTAL PLANT FLOW	121	(9)
Flow Diagrams	121	(3)
Step-by-Step Procedure for Developing a Flow Diagram	124	(1)
The Operations Chart	124	(2)
Step-by-Step Procedures for Preparing an Operations Chart	126	(4)
Flow Process Chart	130	(1)
Step-by-Step Procedure for Preparing a Flow Process Chart	130	(1)
COMPUTER-AIDED FLOW DESIGN AND ANALYSIS	130	(3)
CONCLUSION	133	(1)
QUESTIONS	133	(4)
CHAPTER 6 Activity Relationship Analysis	137	(15)
THE ACTIVITY RELATIONSHIP DIAGRAM	138	(3)
Determining the Relationship Code	140	(1)
WORKSHEET	141	(1)
DIMENSIONLESS BLOCK DIAGRAM	142	(2)
FLOW ANALYSIS	144	(2)
COMPUTER-GENERATED ACTIVITY RELATIONSHIP CHART	146	(4)
QUESTIONS	150	(2)
CHAPTER 7 Ergonomics and Workstation Design Space Requirement	152	(18)
WORKSTATION DESIGN	152	(6)
ERGONOMICS AND THE PRINCIPLES OF MOTION ECONOMY	158	(7)
Principle 1: Hand Motions	159	(1)
Principle 2: Basic Motion Types	160	(1)
Principle 3: Location of Parts and Tools	160	(1)
Principle 4: Free the Hands from as Much Work as Possible	160	(3)
Principle 5: Use Gravity	163	(2)
Principle 6: Operator Safety and Health Considerations	165	(1)
SPACE DETERMINATION	165	(4)
QUESTIONS	169	(1)
CHAPTER 8 Auxiliary Services Requirement Space	170	(37)
RECEIVING AND SHIPPING	170	(10)
The Advantages and Disadvantages of Centralized Receiving and Shipping	170	(1)
The Trucking Industry's Effect on Shipping and Receiving	171	(1)
The Functions of a Receiving Department	171	(2)
Facilities Required for Receiving Departments	173	(2)
Space Requirements for the Receiving Department	175	(1)
The Functions of a Shipping Department	176	(3)
Space Requirements for Shipping Departments	179	(1)
STORAGE	180	(12)
Just-in-Time Inventories	182	(1)
Maximizing the Use of the Cubic Space	182	(2)
Provide Immediate Access to Everything	184	(7)
Provide Safekeeping	191	(1)
WAREHOUSING	192	(11)
Warehouse Design Criteria	193	(1)
The Functions of a Warehouse	194	(2)
Procedure for Sales Analysis of ABC Inventory	196	(2)
ABC Inventory Layout of a Hand Tool Manufacturing Company's Warehouse	198	(2)
Warehouse Space Determination	200	(1)
Warehouse Equipment	201	(2)
Conclusion	203	(1)
MAINTENANCE AND TOOL ROOM	203	(1)
UTILITIES	204	(1)
QUESTIONS	205	(2)
CHAPTER 9 Employee Services--Space Requirements	207	(16)
PARKING LOTS	208	(1)
EMPLOYEE ENTRANCES	209	(2)
LOCKER ROOMS	211	(1)
TOILETS AND RESTROOMS	212	(3)
LUNCH ROOMS	215	(2)
RECREATION	217	(1)
DRINKING FOUNTAINS	218	(1)
AISLES	218	(1)
MEDICAL FACILITIES	219	(1)
BREAK AREAS AND LOUNGES	220	(1)
MISCELLANEOUS EMPLOYEE SERVICES	220	(2)
QUESTIONS	222	(1)
CHAPTER 10 Material Handling	223	(20)
COST JUSTIFICATION	224	(1)
Sample Material Handling Cost Problem	224	(1)
GOALS OF MATERIAL HANDLING	225	(1)
THE 20 PRINCIPLES OF MATERIAL HANDLING	226	(11)
1. The Planning Principle	226	(1)
2. The Systems Principle	227	(1)
3. The Material Flow Principle	228	(1)
4. The Work Simplification Principle	228	(1)
5. Use Gravity	229	(1)
6. Maximize the Building Code	229	(1)
7. Unit Size Principle	230	(1)
8. Mechanization Principle	231	(1)
9. Automation Principle	231	(1)
10. Equipment Selection Principle	231	(2)
11. The Standardization Principle	233	(1)
12. The Adaptability Principle	234	(1)
13. The Dead Weight Principle	234	(1)
14. The Utilization Principle	234	(1)
15. The Maintenance Principle	234	(1)
16. The Obsolescence Principle	235	(1)
17. The Control Principle	235	(1)
18. The Capacity Principle	235	(1)
19. The Performance Principle	236	(1)
20. The Safety Principle	236	(1)
THE MATERIAL HANDLING PROBLEM-SOLVING PROCEDURE	237	(1)
MATERIAL HANDLING CHECKLIST	238	(3)
QUESTIONS	241	(2)
CHAPTER 11 Material Handling Equipment	243	(74)
RECEIVING AND SHIPPING	244	(16)
Receiving and Shipping Docks	244	(2)
Dock Equipment	246	(4)
Moving Equipment	250	(1)
Fork Trucks	250	(6)
Bridge Cranes	256	(1)
Telescopic Conveyor	256	(1)
Weight Scale	257	(1)
Systems Required on Shipping and Receiving Docks	257	(3)
STORES	260	(9)
Storage Units	260	(2)
Stores Mobile Equipment	262	(5)
Systems Required for Stores Department	267	(2)
FABRICATION	269	(20)
Shop Containers	269	(1)
Tubs and Baskets	269	(4)
Workstation Material Handling Devices	273	(1)
Manipulators and Lifting Devices	273	(11)
Mobile Fabrication Equipment	284	(5)
ASSEMBLY AND PAINT	289	(9)
Belt Conveyors	291	(1)
Powered Roller Conveyor	292	(1)
Car-Type Conveyor	292	(1)
Slat Conveyor	292	(2)
Tow Conveyor	294	(1)
Overhead Trolley Conveyor	294	(1)
Power and Free Conveyor	295	(3)
PACKOUT	298	(4)
Box Formers	298	(1)
Automatic Taping, Gluing, and Stapling	298	(1)
Palletizers	298	(2)
Pick and Place Robots	300	(1)
Banding	300	(1)
Stretch Wrap	300	(2)
WAREHOUSING	302	(7)
Picking Carts	302	(1)
Gravity Flow Bins	303	(1)
Tractor-Trailer Picking Cart	303	(2)
Clamp Trucks	305	(1)
Rotary Conveyor Bins	305	(2)
Vertical Warehouse and Picking Cars	307	(1)
Packing Station	307	(1)
Shipping Containers	308	(1)
BULK MATERIAL HANDLING	309	(4)
Bulk Material Conveyors	310	(3)
COMPUTER-INTEGRATED MATERIAL HANDLING SYSTEMS	313	(3)
Cross-Docking and Flow-Through	314	(2)
QUESTIONS	316	(1)
CHAPTER 12 Office Layout Techniques and Space Requirements	317	(25)
GOALS OF OFFICE LAYOUT DESIGN	317	(1)
TYPES OF OFFICE SPACE	318	(7)
Supervisors' Offices	319	(1)
Open Office Space	320	(2)
Conventional Offices	322	(1)
The Modern Office	323	(2)
SPECIAL REQUIREMENTS AND CONSIDERATIONS OF SOME OFFICES	325	(4)
THE TECHNIQUES OF OFFICE LAYOUT	329	(12)
The Organizational Chart	330	(1)
Flowchart	331	(1)
Communications Force Diagram	332	(3)
Activity Relationship Diagram	335	(1)
Activity Worksheet	335	(1)
Dimensionless Block Diagram	336	(2)
Office Space Determination	338	(1)
Detailed Master Layout	339	(2)
QUESTIONS	341	(1)
CHAPTER 13 Area Allocation	342	(10)
SPACE REQUIREMENTS PLANNING: STEP ONE	342	(3)
BUILDING SIZE DETERMINAIION	345	(1)
DIMENSIONLESS BLOCK DIAGRAM	345	(1)
AREA ALLOCATION PROCEDURE	345	(2)
OFFICE AREA ALLOCATION	347	(4)
QUESTIONS	351	(1)
CHAPTER 14 Facilities Design--The Layout	352	(22)
PLOT PLAN	352	(3)
Plant Layout Methods	355	(1)
MASTER PLAN	355	(11)
Advanced Computer Systems	361	(5)
PLANT LAYOUT PROCEDURE--TOOLBOX PLANT	366	(2)
Office Layout for Toolbox Plant	368	(1)
EVALUATION	368	(5)
QUESTIONS	373	(1)
CHAPTER 15 Application of Computer Simulation and Modeling	374	(15)
INTRODUCTION	374	(1)
DEFINING COMPUTER SIMULATION	375	(1)
ADVANTAGES AND DISADVANTAGES OF SIMULATION	376	(1)
SIMULATION IN FACILITIES PLANNING	376	(1)
HOW SIMULATION WORKS	377	(2)
AN OVERVIEW OF LAYOUT AND SIMULATION SOFTWARE	379	(1)
COMPUTER-AIDED LAYOUT DESIGN	379	(7)
Computer-Assisted Layout Performance Analysis	381	(5)
CASE STUDIES	386	(2)
Simulation in Manufacturing	386	(1)
Simulation and Health Care	387	(1)
Waste Handling and Simulation	387	(1)
QUESTIONS	388	(1)
CHAPTER 16 Selling the Layout	389	(8)
THE PROJECT REPORT	389	(3)
THE PRESENTATION	392	(1)
ADJUSTMENTS	392	(1)
APPROVAL	392	(1)
THE REST OF THE PROJECT	393	(4)
Sourcing	393	(1)
Installation	394	(1)
Engineering Plot	394	(1)
Production Start	394	(1)
Debugging and Follow-Up	395	(1)
Conclusion	395	(2)
Answers	397	(14)
Index	411