Table Of ContentEngineering—Industrial & Manufacturing
Heragu
FACILITIES
“… provides a rigorous, and yet succinct
coverage of the modelling, analysis, and de- F
DESIGN
sign of facilities. The book uses simple to un-
A
derstand language and provides illustrative
case studies ... The provision of a software for Fourth Edition
C
layout and other software tools also make the
book highly useful in helping students under- Now in Its Fourth Edition:
stand the practical aspects of implementing Your Guide to Successful Facility Design I
concepts covered in the book.”
Overcome design and planning problems using the L
—Herbert Mapfaira, University of Botswana,
fourth edition of Facilities Design. Dedicated to the
Mechanical & Manufacturing Engineering I
proper design, layout, and location of facilities, this de-
T
finitive guide outlines the main design and operational
problems that occur in manufacturing and service systems, explains the sig- I
nificance of facility design and planning problems, and describes how math- E Fourth Edition
ematical models can be used to help analyze and solve them. Combining theory
S
with practice, this revised work presents state-of-the-art topics in materials
handling, warehousing, and logistics along with real-world examples that em-
phasize the importance of modeling and analysis when determining a solution D
to complex facility design problems.
What’s New in the Fourth Edition: E
The latest version introduces new Additionally, the author: S
material that includes handling • Describes tools commonly used for
I
equipment and systems, and presenting layout designs
G
presents relevant case studies in • Presents traditional models for
each and every chapter. It also facility layout including the popular
provides access to Layout-iQ systematic layout planning (SLP) N
software, data files for many of model in detail
the numerical examples that are • Provides a layout project involving
contained throughout the book, the SLP model
and PowerPoint files for various • Covers group technology and
chapters.
cellular manufacturing at the Fourth
elementary level
Edition
• Includes a project and a case study
on machine grouping and layout
• Considers next-generation factory
• Access online or download to your smartphone, tablet or PC/Mac
• Search the full text of this and other titles you own layouts
• Make and share notes and highlights • Discusses analytical queuing and
• Copy and paste text and figures for use in your own documents
queuing network models, and more Sunderesh S. Heragu
• Customize your view by changing font size and layout
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Fourth Edition
Fourth Edition
Sunderesh S. Heragu
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
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Contents
Preface..............................................................................................................................................xv
Acknowledgments ..........................................................................................................................xvii
Author .............................................................................................................................................xix
Chapter 1 Introduction to Facility Design ....................................................................................1
1.1 Case Study .........................................................................................................1
1.2 Introduction .......................................................................................................4
1.3 Facility Layout ...................................................................................................7
1.4 Types of Layout Problems .................................................................................8
1.4.1 Service Systems Layout Problem .........................................................8
1.4.2 Manufacturing Layout Problem .........................................................12
1.4.3 Warehouse Layout Problem................................................................12
1.4.4 Nontraditional Layout Problems ........................................................14
1.5 Engineering Design Problem Approach ..........................................................15
1.5.1 Identify the Problem ...........................................................................16
1.5.2 Gather the Required Data...................................................................16
1.5.3 Formulate a Model for the Problem ...................................................16
1.5.4 Develop an Algorithm for the Model and Solve It .............................17
1.5.5 Generate Alternate Solutions, Evaluate, and Select ...........................17
1.5.6 Implement the Solution ......................................................................18
1.5.7 Continuously Review after Implementation .......................................19
1.6 Summary .........................................................................................................19
1.7 Review Questions and Exercises .....................................................................19
Chapter 2 Product and Equipment Analysis ...............................................................................21
2.1 Introduction .....................................................................................................21
2.2 Product Analysis ..............................................................................................21
2.2.1 Bill of Materials .................................................................................21
2.2.2 Assembly Charts ................................................................................21
2.2.3 Engineering Drawing .........................................................................24
2.2.4 Route Sheet .........................................................................................24
2.2.5 Operation Process Chart ....................................................................26
2.3 Equipment Selection ........................................................................................28
2.3.1 Traditional Model ...............................................................................30
2.3.2 Queuing Model ...................................................................................31
2.4 Personnel Requirement Analysis .....................................................................32
2.5 Space Requirement and Availability ...............................................................34
2.6 Summary .........................................................................................................36
2.7 Review Questions and Exercises .....................................................................36
Chapter 3 Process and Material Flow Analysis ..........................................................................41
3.1 Fast-Food Industry ...........................................................................................41
3.2 Introduction .....................................................................................................41
3.3 Data Requirement for Layout Decisions .........................................................41
vii
viii Contents
3.3.1 Flow Patterns ......................................................................................42
3.3.1.1 Common Flow Patterns ......................................................42
3.3.1.2 Five Types of Layouts .........................................................44
3.3.2 Flow Process Chart ............................................................................48
3.3.3 Flow Diagram .....................................................................................48
3.3.4 Flow Data ...........................................................................................49
3.3.4.1 Qualitative Flow Data .........................................................49
3.3.4.2 Relationship Chart ..............................................................50
3.3.4.3 Quantitative Flow Data .......................................................52
3.3.5 Distance Measures .............................................................................52
3.3.5.1 Euclidean ............................................................................53
3.3.5.2 Squared Euclidean ..............................................................53
3.3.6 Layout Evaluation Criteria .................................................................55
3.4 Tools for Presenting Layout Designs ...............................................................57
3.4.1 Drawings ............................................................................................57
3.4.2 Templates ............................................................................................57
3.4.3 Three-Dimensional Physical Models .................................................58
3.4.4 Computer Software Tools ...................................................................59
3.5 Guidelines for Data Development and Generation ..........................................59
3.5.1 Obtaining Basic Data .........................................................................60
3.5.2 Product Data Analysis ........................................................................61
3.5.3 Generate Data in Required Format ....................................................63
3.5.4 Sharing Preliminary Data and Obtaining Feedback ..........................66
3.5.5 Documenting Data .............................................................................66
3.6 Case Study: Application of Methodology at a Manufacturing Company .......66
3.7 Summary .........................................................................................................68
3.8 Review Questions and Exercises .....................................................................68
Chapter 4 Traditional Approaches to Facility Layout .................................................................75
4.1 Introduction .....................................................................................................75
4.2 Systematic Layout Planning ............................................................................76
4.3 Special Considerations in Office Layout .........................................................81
4.4 Office Planning Project for a Mortgage Company ..........................................85
4.4.1 Evaluation ...........................................................................................85
4.4.2 Planning .............................................................................................85
4.4.3 Site Selection ......................................................................................86
4.4.4 Design and Layout ..............................................................................86
4.5 Code Compliance, OSHA, ADA Regulations, and Other
Considerations in Facility Design ...................................................................90
4.5.1 Support Facilities ................................................................................90
4.5.1.1 Cafeteria ..............................................................................90
4.5.1.2 Locker Rooms .....................................................................91
4.5.1.3 Water Closets, Sinks, Showers, and Drinking Fountains .....92
4.5.1.4 Parking Lots .......................................................................92
4.5.1.5 Exercise Area ......................................................................93
4.5.2 ADA ...................................................................................................94
4.5.3 OSHA Regulations .............................................................................96
4.5.3.1 Noise ...................................................................................97
4.5.3.2 Lighting...............................................................................98
4.5.3.3 Ventilation ...........................................................................99
