Engineering—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 WITH VITALSOURCE® K26272 EBOOK Cover Image: Courtesy of Oklahoma State University and Savoye Logistics ISBN: 978-1-4987-3289-5 90000 6000 Broken Sound Parkway, NW Suite 300, Boca Raton, FL 33487 711 Third Avenue New York, NY 10017 9 781498 732895 2 Park Square, Milton Park www.crcpress.com Abingdon, Oxon OX14 4RN, UK Accessing the E-book edition Using the VitalSource® ebook DOWNLOAD AND READ OFFLINE Access to the VitalBookTM ebook accompanying this book is To use your ebook offline, download BookShelf to your PC, via VitalSource® Bookshelf – an ebook reader which allows Mac, iOS device, Android device or Kindle Fire, and log in to you to make and share notes and highlights on your ebooks your Bookshelf account to access your ebook: and search across all of the ebooks that you hold on your On your PC/Mac VitalSource Bookshelf. 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SUPPORT If you have any questions about downloading Bookshelf, creating your account, or accessing and using your ebook edition, please visit http://support.vitalsource.com/ 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 CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2016 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Version Date: 20151102 International Standard Book Number-13: 978-1-4987-3290-1 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the valid- ity of all materials or the consequences of their use. 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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