Table Of ContentT H I R D E D I T I O N
MANUFACTURING
FACILITIES
Location, Planning, and Design
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T H I R D E D I T I O N
MANUFACTURING
FACILITIES
Location, Planning, and Design
Dileep R. Sule
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
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CRC Press
Taylor & Francis Group
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© 2008 by Taylor & Francis Group, LLC
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Version Date: 20131121
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Contents
Preface.....................................................................................................................xxi
Chapter 1 Introduction..........................................................................................1
1.1. Nature.and.Scope.of.Part.I.............................................................................1
1.2. Nature.and.Scope.of.Part.II............................................................................3
1.3. The.Role.of.a.Facility.Planner........................................................................5
1.4. Computer.Programs........................................................................................5
Suggested.Readings....................................................................................................6
PART 1 Planning and Design
Chapter 2 Product.Development...........................................................................9
2.1. Market.Research.............................................................................................9
2.1.1. Market.Potential.............................................................................10
2.1.2. Collection.of.Data..........................................................................11
2.1.3. Survey.Form...................................................................................11
2.1.4. Basic.Steps.in.Market.Research.....................................................12
2.1.5. Market.Decision.............................................................................13
2.1.6. An.Example.of.Market.Research...................................................13
2.2. Quality.Function.Deployment......................................................................17
2.3. Forecasting...................................................................................................20
2.3.1. Error.Measuring.............................................................................21
2.3.2. Forecasting.Methods......................................................................21
2.3.2.1. Moving.Average...........................................................21
2.3.2.2. Weighted.Moving.Average...........................................22
2.3.2.3. Exponential.Smoothing................................................23
2.3.2.4. Curve.Fitting................................................................25
2.3.3. Demand.Forecasting.for.a.New.Company.....................................28
2.4. Design...........................................................................................................29
2.5 Design.for.Manufacture................................................................................31
2.5.1. Design.Principles.in.DFM.............................................................31
2.5.2. Concurrent.Engineering.................................................................33
2.5.3. Role.of.QFD,.DFM,.and.CE.in.Facility.Planning.........................33
2.6. Drawings.......................................................................................................34
2.6.1. Bill.of.Materials.............................................................................34
2.6.2. Additional.Drawings......................................................................36
2.7. Economic.Evaluation.of.Processes...............................................................37
2.8. Computer-Aided.Design...............................................................................40
2.9. Computer.Program.Description...................................................................43
2.9.1. Summary........................................................................................43
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Problems...................................................................................................................44
Suggested.Readings..................................................................................................48
Chapter 3 Automation.........................................................................................49
3.1. Sensing.Methods..........................................................................................49
3.2. Bar.Codes.....................................................................................................51
3.2.1. Principles.of.Bar.Code.Technology...............................................51
3.2.2. Bar.Code.Symbologies...................................................................51
3.2.2.1. 2.of.5.Code...................................................................55
3.2.2.2. Interleaved.2.of.5.Code................................................56
3.2.2.3. Code.3.of.9...................................................................57
3.2.3. Universal.Product.Code.................................................................58
3.2.4. Applications.of.the.Bar.Code.........................................................61
3.2.5. Equipment.Used.in.Bar.Code.Applications...................................62
3.2.5.1. Bar.Code.Readers.........................................................63
3.2.5.2. Bar.Code.Printers.........................................................65
3.2.5.3. Bar.Code.Verifiers/Analyzers.......................................66
3.3. Radio.Frequency.Identification.System........................................................66
3.3.1. How.Does.The.RFID.System.Work?.............................................67
3.3.2. Radio.Data.Communication...........................................................68
3.4. Machine.Vision............................................................................................68
3.4.1. Applications.of.Machine.Vision....................................................69
3.4.2. Typical.Machine.Vision.Setup.......................................................70
3.4.3. Uses.of.Machine.Vision.in.Manufacturing....................................71
3.4.4. Two-.and.Three-Dimensional.Machine.Vision.............................71
3.4.5. Machine.Vision.Processing............................................................72
3.5. Voice.Input...................................................................................................77
3.6. Programmable.Logic.Controllers.................................................................77
3.6.1. PLC.in.Material.Handling.............................................................82
3.7. Numerically.Controlled.Machines...............................................................86
3.7.1. Components.of.NC.Machines........................................................86
3.7.1.1. Instructions...................................................................86
3.7.1.2. Control.Unit..................................................................87
3.7.1.3. Machine.Tool................................................................88
3.7.2. Machine.System.............................................................................88
3.7.2.1. Conventional.NC.Machine...........................................88
3.7.2.2. Direct.Numerical.Control.............................................89
3.7.2.3. Computer.Numerical.Control.......................................89
3.7.2.4. Modern.DNC................................................................89
3.7.3. Advantages.of.NC.Machines.........................................................90
3.7.4. Classification.of.NC.Machines......................................................90
3.8. Industrial.Robots..........................................................................................93
3.8.1. Degrees.of.Freedom.......................................................................93
3.8.2. Classification.of.Robots.................................................................94
3.8.3. Robot.Programming.......................................................................94
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3.8.4. Selecting.a.Robot...........................................................................94
3.8.5. Summary........................................................................................95
Problems...................................................................................................................96
Suggested.Readings................................................................................................101
Chapter 4 Production.Charts.and.Systems.......................................................103
4.1. Production.Charts.......................................................................................103
4.1.1. Symbols.and.Descriptions............................................................103
4.1.2. Assembly.and.Operation.Process.Charts.....................................104
4.1.3. Time.Estimates............................................................................106
4.1.4. Routing.Sheet.or.Production.Work.Order....................................107
4.1.5. Other.Charts.................................................................................108
4.1.5.1. Left-Hand,.Right-Hand.Chart....................................108
4.1.5.2. Gang.Chart.................................................................109
4.1.5.3. Gantt.Chart.................................................................110
4.1.5.4. Flow.Process.Chart....................................................111
4.2. Production.Systems....................................................................................111
4.2.1. Job.Shop.Production....................................................................111
4.2.2. Batch.Production..........................................................................113
4.2.3. Mass.Production...........................................................................114
4.2.4. Cellular.and.Flexible.Manufacturing...........................................114
4.3. Cell.Formation.in.Group.Technology........................................................116
4.3.1. Solution.Procedure.......................................................................117
4.3.1.1. Phase.I........................................................................117
4.3.1.2. Phase.II.......................................................................119
4.3.1.3. Phase.III:.Further.Group.Evaluation.with.
Additional.Objectives.................................................123
4.3.1.4. Phase.III.Procedure....................................................123
4.3.2. Layout.Considerations.with.Cellular.Manufacturing..................128
4.4. Labor.Assignments.....................................................................................128
4.4.1. Labor.Assignment.in.Production.Lines.......................................129
4.4.1.1. Labor.Planning...........................................................132
4.4.2. Assembly.Line.Balancing............................................................132
4.4.2.1. Balancing.Procedures.................................................133
4.4.3. Parallel.Grouping.of.Stations.......................................................139
4.4.4. Computerized.Assembly.Line.Programs.....................................141
4.4.4.1. Applicable.Programs.by.Others.................................141
4.5. Computer.Program.Description.................................................................141
4.5.1. Assembly.Line.Balancing.(in.GW-BASIC).................................142
4.5.1.1. Largest.Candidate.Rule..............................................142
4.5.1.2. RPW.Method..............................................................142
4.5.2. GT.Computer.Programs...............................................................142
4.5.2.1. Group..........................................................................143
4.5.2.2. Largroup.....................................................................144
4.6. Summary....................................................................................................144
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Problems.................................................................................................................147
Suggested.Readings................................................................................................152
Chapter 5 Requirements.and.Selection.of.Machines.and.Labor......................155
5.1. Machine.Selection......................................................................................155
5.1.1. Make-or-Buy.Analysis.................................................................155
5.1.2. Sources.of.Information................................................................158
5.1.2.1. Books.and.Periodicals................................................158
5.1.2.2. Computer.Databases...................................................159
5.1.3. Production.Arrangement..............................................................160
5.1.4. Cost.Consideration.......................................................................160
5.1.5. Available.Capacity.......................................................................160
5.1.6. Required.Capacity........................................................................162
5.1.7. Number.of.Machines.Needed......................................................162
5.1.7.1. Extensions.of.Variations.on.Stage.Analysis...............164
5.1.7.2. System.Decomposition...............................................166
5.1.8. Machine.Specifications................................................................169
5.1.9. Auxiliary.Equipment...................................................................171
5.2. Labor.Requirement.and.Selection..............................................................171
5.2.1. Job.Evaluation..............................................................................171
5.2.1.1. Sample.Job.Evaluation:.Machine.Shop.Supervisor....173
5.2.1.2. Sample.Job.Evaluation:.Salary.Determination...........173
5.2.2. Standard.Job.Analysis..................................................................174
5.2.3. Job.Definition.and.Description....................................................175
5.3. Machine.Coupling......................................................................................177
5.3.1. Example.of.Machine.Coupling....................................................177
5.3.1.1. Alternative.A..............................................................177
5.3.1.2. Alternative.B..............................................................178
5.3.1.3. Alternative.C..............................................................178
5.3.1.4. Alternative.D..............................................................180
5.4. Total.Personnel.Requirement.....................................................................181
5.5. Summary....................................................................................................183
Problems.................................................................................................................183
Suggested.Readings................................................................................................187
Chapter 6 Lean.Manufacturing.and.Supply.Chain...........................................189
6.1. Lean.Manufacturing...................................................................................189
6.1.1. 5S.System.....................................................................................190
6.1.1.1. Sort.............................................................................190
6.1.1.2. Straighten....................................................................191
6.1.1.3. Shine...........................................................................193
6.1.1.4. Standardize.................................................................193
6.1.1.5. Sustain........................................................................193
6.1.2. Six.Sigma.....................................................................................194
6.1.2.1. Define.........................................................................194
6.1.2.2. Measure......................................................................194
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6.1.2.3. Analyze.......................................................................195
6.1.2.4. Improve.......................................................................197
6.1.2.5. Control........................................................................197
6.1.2.6. Replicate.....................................................................198
6.1.3. Kaizen.Philosophy.......................................................................198
6.1.4. Andon...........................................................................................199
6.1.5. Takt.Time.....................................................................................200
6.1.6. Single.Minute.Exchange.of.Die...................................................201
6.1.7. Value.Stream.Mapping.................................................................202
6.1.8. Kanban.........................................................................................207
6.1.9. Total.Production.Maintenance.....................................................209
6.1.9.1. Available.Time.on.Machine.......................................209
6.1.9.2. Machine.Speed...........................................................210
6.1.9.3. Increase.Yield.............................................................210
6.1.10. Visual.Management.....................................................................212
6.1.11. Multiskill.Workers.......................................................................213
6.1.12. A.Case.Study.in.Lean..................................................................214
6.1.13. Toyota.Production.System............................................................242
6.2. Supply.Chain..............................................................................................242
6.2.1. Distribution.Problem....................................................................243
6.2.2. Aggregate.Planning.Model..........................................................244
6.2.2.1. Formulation.and.Solution...........................................245
6.2.3. Just-in-Time.Production/Pickups.................................................247
6.2.3.1. Linear.Heuristic.Programming.Formulation.............248
6.3. Summary....................................................................................................251
Problems.................................................................................................................251
Chapter 7 Building,.Organization,.Communications,.
and.Selected.Support.Requirements................................................255
7.1. Building......................................................................................................255
7.1.1. Conventional.Building.Characteristics........................................255
7.1.1.1. Structure.....................................................................256
7.1.1.2. Walls...........................................................................256
7.1.1.3. Floor...........................................................................256
7.1.1.4. Roof............................................................................257
7.1.1.5. Interior........................................................................257
7.1.2. Prefabricated.Buildings................................................................258
7.2. Organization...............................................................................................258
7.2.1. Organizational.Concepts..............................................................258
7.2.2. Organization.Charts.....................................................................259
7.2.3. Organizational.Structures............................................................259
7.2.3.1. Line.Organization.......................................................259
7.2.3.2. Staff-Line.Organization.............................................260
7.2.3.3. Product.Organization.................................................261
7.2.3.4. Matrix.Organization...................................................262
7.2.4. Selection.of.Organization.Structure............................................262
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