CHAPTER1IntroductiontoManufacturingFacilitiesDesignandMaterialHandling
THEIMPORTANCEOFANDMANUFACTURINGFACILITIESDESIGNANDMATERIALHANDLING
LEANTHINKINGANDLEANMANUFACTURING
THEGOALSOFMANUFACTURINGFACilitiesdesignANDMATERIALHANDLING
THEMANUFACTURINGFACILITIESDESIGNPROCEDURE
TYPESANDSOURCESOFMANUFACTURINGFACILITIESDESIGNPROCEDURE
COMPUTERSANDSIMULATIONINMANUFACTURINGFACILITIESDESIGN
ISO9000andFacilitiesPlanning
GLOSSARYOFMAJORTERMS
QUESTIONS
CHAPTER2SourcesofInformationforManufacturingFacilitiesDesignTHEMARKETINGDEPARTMENT
THEPRODUCTDESIGNDEPAR
MANAGEMENTPOLICYINFORMATON
InventoryPolicy
LeanThinkingandMudaasaPartofManagementPolicy
InvestmentPolicy
StartupSchedule
MakeorBuyDecisions
OrganizationalRelationships
FeasibilityStudies
CONCLUSION
QUESTIONS
CHAPER3TimeStudy
WHATISATIMESTANDARD?
IMPORTANCEANDUSESOFTIMESTUDY
1.HowManyMachinesDoWeNeed7
2.HowManyPeopleShouldWeHire?
3.HowMuchWillOurProductCost?
4.WhenShooldWeStartaJob,andHowMuchWorkCanWeHandlewiththeEquipmentandPeopleWeHave?Or,HowDoWeScheduleandLoadMachines,WorkCenters,Departments,andPlants?
5.DeterminetheAssemblyLineBalance,DeterminetheConveyorBeltSpeed,LoadtheWorkCellswiththeConectAmountofWork,andBalancetheWorkCells?
6.HowDoWeMeasureProductivity?
7.HowCanWePayOurPeopleforOutstandingPerformance?
8.HowCanWeSelecttheBestMethodorEvaluateCostReductionIdeas?
9.HowDoYouEvaluateNewEquipmentPurchasestoJustifyTheirExpense?
10.HowDoWeDevelopaPenonnelBudget?
TECHNIQUESOFTIMESTUDY
PredeterminedTimeStandardsSystems
StopwatchTimeStudy
TimeStudyProcedureandtheStep-by-StepForm
PrinciplesofElementalBreakdown
Rating,Leveling,andNormalizing
ALLOWANCES
TypesofAllowances
MethodsofApplyingAllowances
WorkSampling
StandardData
ExpertOpinionTimeStandardsandHistoricalData
TIMESTANDARDSFORMANUFACTURINGFACILIYIESDESIGN
QUESTIONS
CHAPTER4ProcessDesign
FABRICATION:MAKINGTHEINDIVIDUALPARTS
RouteSheets
TheNumberofMachinesNeeded
WORKCELLLOADCHART
Step-by-StepProcedureforPreparingaWorkCellLoadChart
ASSEMBLYANDPACKOUTPROCESSANALYSIS
TheAssemblyChart
TimeStandardsAreRequiredforEveryTask
PlantRateandConveyorSpeed
PainlConveyorSpeed
AssemblyLineBalancing
STEP-BY-STEPPROCEDUREFORCOMPLETNGTHEASSEMBLYLINEBALANCINGFORM
CALCULATINGTHEEFFICIENCYOFTHEASSEMBLYLINEUseofComputerSimulation
LAYOUTORIENTATION
QUESTIONS
CHAPTER5FlowAnalysisTechniques
FABRICATIONOFINDTVIDUALPARTS
StringDiagram
Multi-ColumnProcessChart
From-ToChart
ProcessChart
Step-by-StepDescriptionfortheProcessChart
TOTALPLANTFLOW
FlowDiagrams
Step-by-StepProcedureforDevelopingaFlowDiagram
TheOperationsChart
Step-by-StepProceduresforPreparinganOperationsChart
FlowProcessChart
Step-by-StepProcedureforPreparingaRowProcessChart
COMPUTER-AIDEDFLOWDESIGNANDANALYSIS
CONCLUSION
QUESTIONS
ChAPTER6activityRelationshipAnalysis
THEACTIVITYRELATIONSHIPDIAGRAM
DeterminingtheRelationshipCode
WORKSHEET
DIMENSIONLESSBLOCKDIAGRAM
FLOWANALYSIS
COMPUTER-GENERATEDACTIVITYRELATIONSHIPCHART
QUESTIONS
CHAPTER7ErgonomicsandWorkstationDesignSpaceRequirement
WORKSTATIONDESIGN
ERGONOMICSANDTHEPRINCIPLESOFMOTIONECONOMY
Principle1:HandMotions
Principle2:BasicMotionTypes
Principle3:LocationofPartsandTools
Principle4:FreetheHandsfromasMuchWorkasPossible
Principle5:UseGravity
Principle6:OperatorSafetyandHealthConsiderations
SPACEDETERMINATION
QUESTIONS
CHAPTER8AuxiliaryServicesRequirementSpace
RECEIVINGANDSHIPPING
TheAdvantagesandDisadvantagesofCentralizedReceivingandShipping
TheTruckingIndustry'sEffectonShippingandReceiving
TheFunctionsofaReceivingDepartment
FacilitiesRequiredforReceivingDepartments
SpaceRequirementsfortheReceivingDepartment
TheFunctionsofaShippingDepartment
SpaceRequirementsforShippingDepartments
STORAGE
Just-in-TimeInventories
MaximizingtheUseoftheCubicSpace
ProvideImmediateAccesstoEverything
ProvideSafekeeping
WAREHOUSING
WarehouseDesignCriteria
TheFunctionsofaWarehouse
ProcedureforSalesAnalysisofABCInventory
ABCInventoryLayoutofaHandToolManufacturingCompany'sWarehouse
WarehouseSpaceDetermination
WarehouseEquipment
Conclusion
MAINTENANCEANDTOOLROOM
UTILITIES
QUESTIONS
CHAPTER9EmployeeServices-SpaceRequirements
PARKINGLOTS
EMPLOYEEENTRANECS
LOCKERROOMS
TOLETSANDRBSTROOMS
LUNCHROOMS
RECREATION
DRINKINGFOUNTAINS
AISLES
MEDICALFACILITIES
BREAKAREASANDLOUNGES
MISCELLANEOUSEMPLOYEESERVICES
QUESTIONS
CHAPTER10MaterialHandling
COSTJUSTIFICATION
SampleMaterialHandlingCostProblem
GOALSOFMATERIALHANDLING
THE20PRINCIPLESOFMATERIALHANDLING
1.ThePlanningPrinciple
2.TheSystemsPrinciple
3.TheMaterialFlowPrinciple
4.TheWorkSimplificationPrinciple
5.UseGravity
6.MaximizetheBuildingCode
7.UnitSizePrinciple
S.MechanizationPrinciple
9.AutomationPrinciple
1O.EquipmentSelectionPrinciple
11.TheStandardizationPrinciple
12.TheAdaptabilityPrinciple
13.TheDeadWeightPrinciple
14.TheUtilizationPrinciple
15.TheMaintenancePrinciple
16.TheObsolescencePrinciple
17.TheControlPrinciple
18.TheCapacityPrinciple
19.ThePerformancePrinciple
20.TheSafetyPrinciple
THEMATERIALHANDLINGPROBLEM-SOLVINGPROCEDURE
MATERIALHANDLINGCHECKLIST
QUESTIONS
CHAPTER11MaterialHandlingEquipment
RECEIVINGANDSHIPPING
ReceivingandShippingDocks
DockEquipment
MovingEquipment
ForkTrucks
BridgeCranes
TelescopicConveyor
WeightScale
SystemsRequiredonShippingandReceivingDocks
STORES
StorageUnits
StoresMobileBquipment
SystemsRequiredforStoresDepanment
FABRICATION
ShopContainers
TubsandBaskets
WorkstationMaterialHandlingDevices
ManipulatorsandLiftingDevices
MobileFabricationEquipment
ASSEMBLYANDPAINT
BeltConveyors
PoweredRollerConveyor
Car-typeConveyor
SlatConveyor
TowCoveyor
OverheadTrolleyConveyor
PowerandFreeConveyor
PACKOUT
BoxFormers
AatomaticTaping,Gluing,andStapling
Palletizers
PickandPlaceRobots
Banding
StretchWrap
WAREHOUSING
PickingCarts
GravityFlowBins
Tractor-TrailerPickingCart
ClampTrucks
RotaryConveyorBins
VerticalWarehouseandPickingCars
PackingStation
ShippingContainers
BULKMATERIALHANDLING
BulkMaterialConveyors
COMPUTER-INTEGRATEDMATERIALHANDLINGSYSTEMS
Cross-DockingandFlow-Through
QUESTIONS
CHAPTER12OfficeLayoutTechniquesandSpaceRequirements
GOALSOFOFFICELAYOUTDESIGN
TYPESOFOFFICESPACE
Supervisors'Offices
OpenOfficeSpace
ConventionalOffices
TheModernOffice
SPECIALREQUIREMENTSANDCONSIDERATIONSOFSOMEOFFICES
THETECHNIQUESOFOFFICELAYOUT
TheOrganizationalChart
Flowchart
CommunicationsForceDiagram
ActivityRelationshipDiagram
ActivityWorksheet
DimensionlessBlockDiagram
OfficeSpaceDetermination
DetailedMasterLayout
QUESTIONS
CHAPTER13AreaAllocation
SPACEREQUIREMENTSPLANNING:STEPONE
BUILDINGSIZEDETERMINATION
DIMENSIONLESSBLOCKDIAGRAM
AREAALLOCATIONPROCEDURE
OFFICEAREAALLOCATION
QUESTIONS
CHAPTER14FacilitiesDesign-TheLayout
PLOTPLAN
PlantLayoutMethods
MASTERPLAN
AdvancedComputerSystems
PLANTLAYOUTPROCEDURE--TOOLBOXPLANT
OfficeLayoutforToolboxPlant
EVALUATION
QUESTIONS
CHAPTER15ApplicationofComputerSimulationandModeling
INTRODUCTION
DEFININGCOMPUTERSIMULATION
ADVANTAGESANDDISADVANTAGESOFSIMULATION
SIMULATIONINFACILITIESPLANNING
HOWSIMULATIONWORKS
ANOVERVIEWOFLAYOUTANDSIMULATIONSOFTWARE
COMPUTER-AIDEDLAYOUTDESIGN
Computer-AssistedLayoutPerformanceAnalysis
CASESTUDIES
SimulationinManufacturing
SimulationandHealthCare
WasteHandlingandSimulation
QUESTIONS
CHAPTER16SellingtheLayout
THEPROJECTREPORT
THEPRESENTATION
ADJUSTMENTS
APPROVAL
THERESTOFTHEPROJECT
Sourcing
Installation
EngineeringPlot
ProductionStart
DebuggingandPollow-Up
Conclusion
Answers
Index
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