PVT ATTY mT eT SHAAN sc MEL S59)FACILITIES PLANNING ‘THIRD EDITION JAMES A. TOMPKINS. JOHN A. WHITE University of Arkansas YAVUZ A. BOZER Daiversity of Michigan J. M.A. TANCHOCO ‘unde University ® JOHN WILEY & SONS, INC.CONTENTS Part One DEFINING REQUIREMENTS — 1 Chapter One INTRODUCTION 3 11. Facilities Planning Defined 3 12. Significance of Facilities Planning 9 13. Objectives of Facilities Planning 12 14 Facilities Planning Process 13 15° Steategic Facilities Planning 19 16 Developing Facilities Planning Strategies 27 1.7, Examples of Inadequate Planning — 25 18 Summary 26 Bibliography 27 Problems 28 Chapter Two PRODUCT, PROCESS, AND SCHEDULE DESIGN’ 30 21 Introduction 30 22 Product Design 32 23. Process Design 36 24 Schedule Design 47 25. Facilities Design — 62 26 Summary 70 Bibliogeaphy 72 Problems 73 Chapter Three FLOW, SPACE, AND ACTIVITY RELATIONSHIPS 79 1 Introduction 79 32 Departmental Planning 80 33. Activity Relationships 9234 Flow Patterns 98 35. Flow Plan: 101 36 Measuring Flow 103 37 Space Requirements 109 38 8 Bibliography 119) Problems 121 ary 118 (Chapter Four PERSONNEL REQUIREMENTS 125 41 Inteoduction 125 42. The Employee-Facility Interface 126 43° Restrooms 134 44 Food Services 139 45° Health Services 144 46 Barrler-free Compliance 145 47 Office Facility Planning — 148 48 Summary 158 158 Part Two DEVELOPING ALTERNATIVES: CONCEPTS IND TECHNIQUES 161 Chapter Flue MATERIAL HANDLING 163 51 Introduction — 163 5.2. Scope and Definitions of Material Handling 164 5.3 Material Handling Principles 167 54 Designing Material Handling Systems 169 55 Unit Load Design 174 56 Material Handling Equipment 191 5.7 Estimating Material Handling Costs 196 5.8 Safety Considerations 197 59 Summary 199ibliogeaphy 200 | Problems 203 Appendix 54 Material Handling Audit Checklist 205 Appendix 5# Material Handling Equipment 214 Appendix 5c Automated Guided Vehicle Systems 290 Chapter Ste LAYOUT PLANNING MODELS AND DESIGN ALGORITHMS 298 G1 Introduction 298 62 Basie Layout Types 299 63 Layout Procedures 301 G4 Algorithmic Approaches 309 65 Department Shapes and Main Aisles 348 66 Simulated Annealing and Genetic Algorithms 351 6&7 Multifloor Facility Layout 357 68 Commercial Facility Layout Packages 367 69 The Impact of Change 362 6.10 Developing Layout Alternatives 368 611 Summary 370 Bibliography — 372 Appendix 64 ALDEP and CORFLAP 376 | GAL Introduction 376 GA2 CORELAP 376 GAZ ALDEP 380 Problems 384 | Part Three | FACILITY DESIGN FOR VARIOUS | FACILITIES FUNCTIONS — 399 Chapter Seven WAREHOU 7A Introduction 401 7.2 Missions of a Warehouse 403 7.3 Functions i the Warehouse 404 SE OPERATIONS 401Receiving and Shipping Operations 406 Dock Locations 429 Storage Operations 430 ‘Order Picking Operations 447 ymmary 457 Bibliography 457 Problems 459 Chapter Bight MANUFACTURING SYSTEMS 464 81 Introduction 464 82 Fixed Automation Systems 467 83 Flexible Manufacturing Systems 469 84 SingleStage Mult-Machine Systems 472 85. Reduction of Workin-Process 474 86 Justin-Time Manufscwwring 475 87 Facilities Planning Trends 483 88 Summary 484 Bibliography 484 Problems 487 Chapter Nine FACILITIES SYSTEMS 9.1 Introduction 489 9.2 Structural System Performance 9.3 Enclosure Systems 493 9.4 Atmospheric Systems 496 9.5 Electrical and Lighting Systems 9.6 Life Safety Systems 514 9.7 Sanitation Systems 519 9.8 Building Automation Systems 522 99° Facility Maintenance Management Systems 523, 9.40 Summary 524 Bibliography 524 Problems 525— Part Four DEVELOPING ALTERNATIVES: QUANTITATIVE APPROACHES 529 Chapter Ten QUANTITATIVE FACILITIES PLANNING MODELS 531 101 Introduction 531 102 Facility Location Models 532 103 Special Facility Layout Models 544 104 Machine Layout Models 553 105 Conventional Storage Models 555 106 Awtomated Storage and Retrieval Systems 566 10.7 Order Picking Systems 578 108 ¥ixed-Path Material Handling Models 592 109. Waiting Line Models 618 10.10 Simulation Models 639 10.11 Summary 643 Bibliography — 643, Problems 646 Part Five EVALUATING, SELECTING, PREPARING, PRESENTING, IMPLEMENTING, AND MAINTAINING 675 Chapter Eleven EVALUATING AND SELECTIN FACILITIES PLAN 677 111 Introduction 677 112. Evaluating Facilides Plans 650 113. Selecting the Facilities Plans 703 114 Summary 703 Bibliography 704 Problems 705Chapter Twelve PREPARING, PRESENTING, IMPLEMENTING, at 122 123 24 Bs 126 AND MAINTAINING THE FACILITIES PLAN 708 08 Preparing the Facil Presenting the Facilities Plan 720 Implementing the Facilities Pl ntroduction Maintaining the Facilities Plan 731 Summary 731 Bibliography — 732 Problems 733 INDEX 735No more business as usual Pee a ce ee ea een ee eee og rt eat amet eee ee eee a ae Updated withthe latest advances, FACILITIS PLANNING, THIRD EDITION Ee eet tee ee eee eee ee Cee ee ee eee tas planning process from defining requirements todevelopingalternative | See) eee an ee chniques and manufacturinghwarehouse operations to er ee ee ee oes Beene GCRn Car Bee ee eee ge ete eee en aes See ee Cae ce eas te ee eC ena Seen eee een eee help you apply the material to your work Sere eee ee cee See eee ee oan ISON O-473-44389-5 ' sy IAL e ad 7