Manufacturing. Material Handling. Facilities Design and FIFTH EDITION. Matthew P. Stephens. Fred E. Meyers. Purdue University Press

Transcription

1 Manufacturing Facilities Design and Material Handling FIFTH EDITION Matthew P. Stephens Fred E. Meyers Purdue University Press West Lafayette, Indiana

2 Contents CHAPTER 1 INTRODUCTION TO MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING 1 Objectives 1 The Importance of Manufacturing Facilities Design and Material Handling 1 Lean Thinking and Lean Manufacturing 4 The Goals of Manufacturing Facilities Design and Material Handling 6 The Manufacturing Facilities Design Procedure 12 Types and Sources of Manufacturing Facilities Design Projects 14 Computers and Simulation in Manufacturing Facilities Design 15 ISO 9000 and Facilities Planning 16 Glossary of Some Major Terms and Concepts in Facilities Planning 18 Questions 21 CHAPTER 2 SOURCES OF INFORMATIONFOR MANUFACTURING FACILITIES DESIGN 22 Objectives 22 The Marketing Department 23 Determining Takt Time or Plant Rate 24 Calculating Scrap and Rework Rates 25 The Product Design Department 27 Tke Indented Bill of Material 32 Management Policy Inventory Policy 36 Information 36 Lean Thinking and Muda as Part ofmanagement Policy 36 Investment Policy 37 Startup Schedule 37 Make or Buy Decisions 38 Organizational Relationships 39 Feasibility Studies 39 Conclusion 40 Questions 41 xiii

3 xiv CONTENTS CHAPTER 3 TIME STUDY 42 Objectives 42 What is a Time Standard? 43 The Importance and Uses of Time Study 44 /. How Many Machines Do We Need? How Many People Should We Hire? How Much Will Our Product Cost? When Should We Start ajob, and How Much Work Can We Handle with the Equipment and People We Have? Or, How Do We Schedule and Load Machines, Work Centers, Departments, and Plants? How Do We Determine the Assembly Line Balance and the Conveyor Belt Speed, Load the Work Cells with the Correct Amount of Work, and Balance the Work Cells? How Do We Measure Productivity? How Can We Pay Our People for Outstanding Performance? How Can We Select the Best Method or Evaluate Cost Reduction Ideas? How Do We Evaluate New Equipment Purchases to Justify Their Expense? 57 / 0. How Do We Develop a Personnel Budget? 57 Techniques oftime Study 57 Predetermined Time Standards Systems 58 Stopwatch Time Study 58 Time Study Procedure and the Step-by-Step Rating, Leveling, and Normalizing 71 Allowances 73 Types ofallowances 73 Methods of Applying Allowances 77 Work Sampling 80 StandardData 81 Form 62 Expert Opinion Time Standards and Historical Data 82 Time Standards for Manufacturing Facilities Design 83 Questions 84 CHAPTER 4 PROCESS DESIGN 86 Objectives 86 Fabrication: Making the Individual Parts 87 Route Sheets 87 The Number of Machines Needed 91 Work Cell Load Chart 92 Step-by-Step Procedure a for Preparing Work Cell Load Chart 94

4 Contents xv Assembly and Packout Process Analysis 97 The Assembly Chart 97 Time Standards for Every Task 97 Plant Rate and Conveyor Speed 97 Paint Conveyor Speed 99 Assembly Line Balancing 101 Step-by-Step Procedure for Completing the Assembly Line Balancing Form 105 Calculating the Efficiency of the Assembly Line 108 Use of Computer Simulation 109 Layout Orientation 112 Questions 113 CHAPTER 5 FLOWANALYSIS TECHNIQUES 115 Objectives 115 Fabrication of Individual Parts 119 String Diagram 119 Multicolumn Process Chart 121 From-To Chart 123 Process Chart 125 Step-by-Step Description for the Process Chart 127 Total Plant Flow 131 How Diagrams 131 Step-by-Step Procedure for Developing a Flow Diagram 134 The Operations Chart 135 Step-by-Step Procedure for Preparing an Operations Chart 135 Flow Process Chart 137 Step-by-Step Procedure for Preparing a Flow Process Chart 139 Computer-Aided Flow Design and Analysis 139 Conclusion 144 Questions 144 CHAPTER 6 ACTIVITYRELATIONSHIPANALYSIS 145 Objectives 145 Activity Relationship Diagram 146 Determining the Relationship Code 148 Worksheet 150 Dimensionless Block Diagram 150

5 xvi CONTENTS Flow Analysis 153 Computer-Generated Activity Relationship Chart 153 Questions 156 CHAPTER 7 ERGONOMICS AND WORKSTATION DESIGN SPACE REQUIREMENTS 158 Objectives 158 Workstation Design 158 Ergonomics and the Principles of Motion Economy 160 Principle 1: Hand Motions 161 Principle 2: Basic Motion Types 165 Principle 3: Location ofparts and Tools 166 Principle 4: Freeing the Hands from as Much Work as Possible 168 Principle 5: Gravity 169 Principle 6: Operator Safety Space Determination 170 Questions 173 and Health Considerations 169 CHAPTER 8 AUXILIARYSERVICES REQUIREMENT SPACE 174 Objectives 174 Receiving and Shipping 174 Advantages and Disadvantages of Centralized Receiving and Shipping 175 The Trucking Industry's Effect on Receiving and Shipping 175 Functions of a Receiving Department 176 Facilities Requiredfor a Receiving Department 178 Space Requirementsfor a ReceivingDepartment 180 Functions of a Shipping Department 180 Storage 186 Just-in-Time Inventories 188 Maximizing the Use of the Cubic Space 188 Providing Immediate Access to Everything (Selectivity) 190 Providing Safekeeping 199 Warehousing 199 Warehouse Design Criteria 200 Functions of a Warehouse 202 Procedure for Sales Analysis of ABC Inventory 203 ABC Inventory Layout of a Hand Tool Manufacturing Company's Warehouse 204 Warehouse Space Determination 207 Warehouse Equipment 209 Conclusion 209

6 Maintenance and Tool Room 211 Utilities, Heating, and Air Conditioning 212 Questions 212 CHAPTER 9 EMPLOYEE SERVICES SPACE REQUIREMENTS 214 Objectives 214 Parking Lots 215 Employee Entrance 217 Locker Rooms 219 Restrooms and Toilets 220 Cafeterias or Lunchrooms 220 Recreational Facilities 225 Drinking Aisles 225 Fountains 225 Medical Facilities 226 Break Areas and Lounges 228 Miscellaneous Employee Services 228 Questions 230 CHAPTER 10 MATERIAL HANDLING 231 Objectives 231 Cost Justification 232 Sample Material Handling Cost Problem 233 Goals of Material Handling 234 Ten Principles of Material Handling 234 Planning Principle 239 Systems Principle 241 Work Principle 242 Space Utilization Principle 242 Unit Load Principle 243 Automation Principle 244 Standardization Principle 244 The Material Handling Problem-Solving Procedure 245 Questions 250

7 xviii CONTENTS CHAPTER 11 MATERIAL HANDLING EQUIPMENT 251 Objectives 251 Receiving and Shipping 252 Receiving and Shipping Docks 252 Dock Equipment 256 MovingEquipment 256 Telescopic Conveyor 261 Weight Scale 263 Systems Required on Receiving and Shipping Docks 263 Stores 264 Storage Units 264 Stores Mobile Equipment 267 Systems Required for the Stores Department 269 Fabrication 273 Shop Containers 273 Tubs and Baskets 274 Workstation Material Handling Devices 278 Manipulators and Lifting Devices 278 Mobile Fabrication Equipment 285 Assembly and Paint 292 Belt Conveyors 293 Powered Roller Conveyors 293 Car-Type Conveyors 294 Slat Conveyors 294 Tow Conveyors 295 Overhead Trolley Conveyors 296 Power and Free Conveyors 298 Packout 298 Box Formers 299 Automatic Taping, Gluing, and Stapling 299 Palletizers 301 Pick and Place Robots 301 Banding 301 Stretch Wrap 306 Warehousing 306 Picking Carts 306 Gravity Flow Bins 306 Tractor-Trailer Picking Carts 306 Clamp Trucks 306 Rotary Conveyor Bins 310 Vertical Warehouse and Picking Cars 310 Packing Station 312 Shipping Containers 312

8 Contents xix Bulk Material Handling 315 Bulk Material Conveyors 316 Computer-Integrated Material Handling Systems 318 Cross-Docking and Flow-Through 318 Questions 324 CHAPTER 12 OFFICE LAYOUT TECHNIQUES AND SPACE REQUIREMENTS 325 Objectives 325 Goals of Office Layout Design 326 Types of Office Space 327 Supervisors'Offices 327 Open Office Space 327 Conventional Offices 330 The Modern Office 330 Special Requirements and Considerations 333 Techniques of Office Layout 337 Organizational Chart 338 Flowchart 339 Communications Force Diagram 339 Activity Relationship Diagram 342 Activity Worksheet 343 Dimensionless Block Diagram 344 Office Space Determination 347 Detailed Master Layout 347 Questions 349 CHAPTER 13 AREA ALLOCATION 350 Objectives 350 Space Requirements Planning 350 Under the Floor 352 Overhead or Clear Space Areas 352 Truss Level 353 Roof 353 Building Size Determination 353 Dimensionless Block Diagram 354 Area Allocation Procedure 355 Office Area Allocation 356 Questions 360

9 CONTENTS CHAPTER 14 FACILITIES DESIGN THE LAYOUT 361 Objectives 361 Plot Plan 361 Plant Layout Methods 364 Master Plan 365 Three-Dimensional (3-D) Models 368 Computer-Aided Design (CAD) Technique 368 Advanced Computer Systems 369 Plant Layout Procedure Toolbox Plant 372 Office Layout for the Toolbox Plant 375 Evaluation 377 Questions 382 CHAPTER 15 APPLICATION OF COMPUTER SIMULATION AND MODELING 383 Objectives 383 Introduction 383 Defining Computer Simulation 384 Advantages and Disadvantages of Simulation 385 Simulation in Facilities Planning 386 How Simulation Works 387 An Overview of Layout and Simulation Software 389 Computer-Aided Layout Design 389 Computer-Assisted Layout Performance Analysis 391 Layout-iQ: Computer-based Workspace Planning 397 Process-Routing 398 From-To Trips 399 Subjective Analysis 399 Model Building Wizard 400 Tutorials and Modeling Exercises 401 Case Studies 401 Simulation in Manufacturing 401 Simulation in Health Care 401 Simulation in Waste Handling 402 Questions 403 CHAPTER 16 SELLING THE LAYOUT 404 Objectives 404 The Project Report 404

10 Contents xxi The Presentation 406 Adjustments 407 Approval 407 The Rest of the Project 408 Sourcing 408 Installation 408 Engineering Plot 409 Production Start 409 Debugging and Follow-Up 409 Conclusion 410 ANSWERS 411 APPENDIX 423 INDEX 496