Manufacturing Facilities Design & Material Handling by Stephens, Matthew P. -- Read -- Imperial Library of Trantor

Index

Cover Title Copyright Dedication Preface Acknowledgments About the Authors Contents Chapter 1 Introduction to Manufacturing Facilities Design and Material Handling

Objectives The Importance of Manufacturing Facilities Design and Material Handling Lean Thinking and Lean Manufacturing The Goals of Manufacturing Facilities Design and Material Handling The Manufacturing Facilities Design Procedure Types and Sources of Manufacturing Facilities Design Projects Computers and Simulation in Manufacturing Facilities Design

ISO 9000 and Facilities Planning

Glossary of Some Major Terms and Concepts in Facilities Planning Questions

Chapter 2 Sources Of Information For Manufacturing Facilities Design

Objectives The Marketing Department

Determining Takt Time or Plant Rate Calculating Scrap and Rework Rates

The Product Design Department

The Indented Bill of Material

Management Policy Information

Inventory Policy Lean Thinking and Muda as Part of Management Policy Investment Policy Startup Schedule Make or Buy Decisions Organizational Relationships Feasibility Studies

Conclusion Questions

Chapter 3 Time Study

Objectives What is a Time Standard? The Importance and Uses of Time Study

1. How Many Machines Do We Need? 2. How Many People Should We Hire? 3. How Much Will Our Product Cost? 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? 5. How Do We Determine the Assembly Line Balance and the Conveyor Belt Speed, Load the Work Cells with the Correct Amount of Work, and Balance the Work Cells? 6. How Do We Measure Productivity? 7. How Can We Pay Our People for Outstanding Performance? 8. How Can We Select the Best Method or Evaluate Cost Reduction Ideas? 9. How Do We Evaluate New Equipment Purchases to Justify Their Expense? 10. How Do We Develop a Personnel Budget?

Techniques of Time Study

Predetermined Time Standards Systems Stopwatch Time Study

Time Study Procedure and the Step-by-Step Form

Rating, Leveling, and Normalizing

Allowances

Types of Allowances Methods of Applying Allowances Work Sampling Standard Data Expert Opinion Time Standards and Historical Data

Time Standards for Manufacturing Facilities Design Questions

Chapter 4 Process Design

Objectives Fabrication: Making the Individual Parts

Route Sheets The Number of Machines Needed

Work Cell Load Chart

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

Assembly and Packout Process Analysis

The Assembly Chart Time Standards for Every Task Plant Rate and Conveyor Speed Paint Conveyor Speed Assembly Line Balancing

Step-by-Step Procedure for Completing the Assembly Line Balancing Form Calculating the Efficiency of the Assembly Line

Use of Computer Simulation Layout Orientation

Questions

Chapter 5 Flow Analysis Techniques

Objectives Fabrication of Individual Parts

String Diagram Multicolumn Process Chart From-To Chart Process Chart Step-by-Step Description for the Process Chart

Total Plant Flow

Flow Diagrams Step-by-Step Procedure for Developing a Flow Diagram The Operations Chart Step-by-Step Procedure for Preparing an Operations Chart Flow Process Chart Step-by-Step Procedure for Preparing a Flow Process Chart

Computer-Aided Flow Design and Analysis Conclusion Questions

Chapter 6 Activity Relationship Analysis

Objectives Activity Relationship Diagram

Determining the Relationship Code

Worksheet Dimensionless Block Diagram Flow Analysis Computer-Generated Activity Relationship Chart Questions

Chapter 7 Ergonomics And Workstation Design Space Requirements

Objectives Workstation Design Ergonomics and the Principles of Motion Economy

Principle 1: Hand Motions Principle 2: Basic Motion Types Principle 3: Location of Parts and Took Principle 4: Freeing the Hands from as Much Work as Possible Principle 5: Gravity Principle 6: Operator Safety and Health Considerations

Space Determination Questions

Chapter 8 Auxiliary Services Requirement Space

Objectives Receiving and Shipping

Advantages and Disadvantages of Centralized Receiving and Shipping The Trucking Industry’s Effect on Receiving and Shipping Functions of a Receiving Department Facilities Required for a Receiving Department Space Requirements for a Receiving Department Functions of a Shipping Department

Storage

Just-in-Time Inventories Maximizing the Use of the Cubic Space Providing Immediate Access to Everything (Selectivity)

Warehousing

Warehouse Design Criteria

Functions of a Warehouse

Procedure for Sales Analysis of ABC Inventory

ABC Inventory Layout of aHand Tool Manufacturing Company’s Warehouse Warehouse Space Determination Warehouse Equipment Conclusion

Maintenance and Tool Room Utilities, Heating, and Air Conditioning Questions Chapter 9 Employee Services—Space Requirements

Objectives Parking Lots Employee Entrance Locker Rooms Restrooms and Toilets Cafeterias or Lunchrooms Recreational Facilities Drinking Fountains Aisles Medical Facilities Break Areas and Lounges Miscellaneous Employee Services Questions

Chapter 10 Material Handling

Objectives Cost Justification Sample Material Handling Cost Problem Goals of Material Handling Ten Principles of Material Handling

Planning Principle Systems Principle Work Principle Space Utilization Principle Unit Load Principle Automation Principle Standardization Principle

The Material Handling Problem-Solving Procedure Questions

Chapter 11 Material Handling Equipment

Objectives Receiving and Shipping

Receiving and Shipping Docks Dock Equipment Moving Equipment Telescopic Conveyor Weight Scale Systems Required on Receiving and Shipping Docks

Stores

Storage Units Stores Mobile Equipment Systems Required for the Stores Department

Fabrication Shop Containers

Tubs and Baskets Workstation Material Handling Devices Manipulators and Lifting Devices Mobile Fabrication Equipment

Assembly and Paint

Belt Conveyors Powered Roller Conveyors Car-Type Conveyors Slat Conveyors Tow Conveyors Overhead Trolley Conveyors Power and Free Conveyors

Packout

Box Formers Automatic Taping, Gluing, and Stapling Palletizers Pick and Place Robots Banding Stretch Wrap

Warehousing

Picking Carts Gravity Flow Bins Tractor-Trailer Picking Carts Clamp Trucks Rotary Conveyor Bins Vertical Warehouse and Picking Cars Packing Station Shipping Containers

Bulk Material Handling

Bulk Material Conveyors

Computer-Integrated Material Handling Systems

Cross-Docking and Now-Through

Questions

Chapter 12 Office Layout Techniques And Space Requirements

Objectives Goals of Office Layout Design Types of Office Space

Supervisors’ Offices Open Office Space Conventional Offices The Modern Office

Special Requirements and Considerations Techniques of Office Layout

Organizational Chart Flowchart Communications Force Diagram Activity Relationship Diagram Activity Worksheet Dimensionless Block Diagram Office Space Determination Detailed Master Layout

Questions

Chapter 13 Area Allocation

Objectives Space Requirements Planning

Under the Floor Overhead or Clear Space Areas Truss Level Roof

Building Size Determination Dimensionless Block Diagram Area Allocation Procedure Office Area Allocation Questions

Chapter 14 Facilities Design—The Layout

Objectives Plot Plan Plant Layout Methods Master Plan

Three-Dimensional (3-D) Models Computer-Aided Design (CAD) Technique Advanced Computer Systems

Plant Layout Procedure—Toolbox Plant

Office Layout for the Toolbox Plant

Evaluation Questions

Chapter 15 Appucation Of Computersimulation And Modeling

Objectives Introduction Defining Computer Simulation Advantages and Disadvantages of Simulation Simulation in Facilities Planning How Simulation Works An Overview of Layout and Simulation Software Computer-Aided Layout Design

Computer-Assisted Layout Performance Analysis

Layout-iQ: Computer-based Workspace Planning

Process-Routing From-To Trips Subjective Analysis Model Building Wizard Tutorials and Modeling Exercises

Case Studies

Simulation in Manufacturing Simulation in Health Care Simulation in Waste Handling

Questions

Chapter 16 Selling The Layout

Objectives The Project Report The Presentation Adjustments Approval The Rest of the Project

Sourcing Installation Engineering Pilot Production Start Debugging and Follow-Up

Conclusion

Answers Appendix Index

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