Facilities planning

866 Pages·2010·34.422 MB·English

by  Tompkins, James A

Facilities
Planning
FOURTH EDITION
T O M P K I N S | W H I T E | B O Z E R | TA N C H O C O
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FACILITIES
PLANNING
FOURTH EDITION
JAMES A. TOMPKINS
Tompkins Associates, Inc.
JOHN A. WHITE
University of Arkansas
YAVUZ A. BOZER
University of Michigan
J. M. A. TANCHOCO
Purdue University
JOHN WILEY & SONS, INC.
V.P. AND EXECUTIVE PUBLISHER Don Fowley
ACQUISITION EDITOR Jenny Welter
EDITORIAL ASSISTANT Alexandra Spicehandler
MARKETING MANAGER Christopher Ruel
DESIGN DIRECTOR Harry Nolan
SENIOR DESIGNER Kevin Murphy
COVER PHOTOS (center) Walter Hodges/Getty Images, Inc.; (top right inset) EIGHTFISH/Getty
Images, Inc.; (center right inset) Courtesy of Tompkins Associates, Inc.; (bottom right inset) Matthew
Rambo/iStockphoto
PRODUCTION MANAGEMENT SERVICES Suzanne Ingrao/Ingrao Associates
This book was set in 10/12 Garamond by Aptara®, Inc. and printed and bound by Hamilton Printing Co.
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ISBN: 978-0-470-44404-7
Printed in the United States of America
10 9 8 7 6 5 4 3 2 1
PREFACE
The fourth edition of Facilities Planning is a comprehensive up-to-date text on the
art and science of planning facilities. The purpose of this book is to continue the
creativity, rigor, and design aspects of facilities planning while rejecting the cook-
book and checklist approaches to this discipline.
Because it impacts so many activities and has such a major impact on the suc-
cess of the functions within the facilities, the importance of facilities planning will
continue to grow and challenge the engineering professional. The role of facilities
in the context of the dynamic global supply chain continues to make it very impor-
tant for new professionals to have a depth of understanding of facilities planning.
In this fourth edition, we have reexamined the role of facilities planning
within the supply chain. It is now imperative that the facilities planner assist his or
her company in progressing through the six levels of supply chain excellence:
Business as Usual, Link Excellence, Visibility, Collaboration, Synthesis, and Velocity.
Successful enterprises know that there is no more “business as usual.” Facilities
planning is no longer just the task of planning facilities but a strategy for navigat-
ing a competitive global economy. Every entity must insist on facilities that support
the success of the business both short and long form. We also examine how lean
manufacturing has impacted facilities planning, and in particular, we stress the impor-
tance of developing a Future State Map in defining the departments that constitute
the facility.
In this edition, we endeavor to continue the engineering design process and
application of quantitative tools as a foundation for executing appropriate and suc-
cessful facilities planning. We have given more detailed real-world examples and
problems concerning current facilities planning practices and deleted dated material.
We have added new photography of the industry’s latest material handling equipment
and updated the drawing and diagrams to better reflect the practices taking place
today. The instructor will find improved problem sets, including more quantitative
problems, and a greater variety of helpful questions.
The text is organized as follows:
● Defining Requirements
— Strategic Facilities Planning
— Product, Process, and Schedule Design
— Flow Systems, Activity Relationships, and Space Requirements
— Personnel Requirements
● Developing Alternatives: Concepts and Techniques
— Material Handling
— Layout Planning Models and Design Algorithms
● Developing Alternatives: Functions
— Warehouse Operations
— Manufacturing Operations
— Facilities Systems
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iv
Preface
● Developing Alternatives: Quantitative Approaches
— Quantitative Facilities Planning Models
— Evaluating, Selecting Preparing, Presenting, Implementing, and Maintaining
● Evaluating and Selecting the Facilities Plan
— Preparing, Presenting, Implementing, and Maintaining Facilities Plans
The instructor can easily rearrange the material as best suited for his or her method
of instruction.
Resources available to instructors adopting this text include the Instructor
Solutions Manual, and an Image Gallery of the illustrations from the text in a format
appropriate for inclusion in lecture slides. Visit the publisher website at www.
wiley.com/college/tompkins to register for a password and access these resources.
Many people have influenced the development of this text. Deserving special
mention are Marvin H. Agee, James M. Apple, James M. Apple, Jr., Robert P. Davis,
Marc Goetschalckx, Kevin R. Gue, Hugh D. Kinney, Leon F. McGinnis, Russell D.
Meller, Benoit Montreuil, Colin L. Moodie, James M. Moore, Richard Muther, Ruddell
Reed, Jr., Jerry D. Smith, John D. Spain, John A. White III, Richard A. Wysk, and
Kazuho Yoshimoto, whose professionalism and expertise have influenced our
thinking on the subject. Also we thank Jenny Welter and Bill Webber of John Wiley,
Paul Faber, Mike Halsey, Todd Heaward, Jackie Montgomery and Dale Pickett
of Tompkins Associates, Brent Tymensky of Fortna Inc., Jeff Shannon at the
University of Arkansas, and Patrick Brunese at Purdue University.
Finally, we thank our families for their patience, support, and encouragement
while we worked to create a teaching tool that reflects our collective vision of facil-
ities planning excellence.
James A. Tompkins
John A. White
Yavuz A. Bozer
J. M. A. Tanchoco
CONTENTS
Part One
DEFINING REQUIREMENTS 1
Chapter One INTRODUCTION 3
1.1 Facilities Planning Defined 3
1.2 Significance of Facilities Planning 9
1.3 Objectives of Facilities Planning 12
1.4 Facilities Planning Process 13
1.5 Strategic Facilities Planning 18
1.6 Developing Facilities Planning Strategies 21
1.7 Examples of Inadequate Planning 24
1.8 Summary 26
References 27
Problems 28
Chapter Two PRODUCT, PROCESS, AND
SCHEDULE DESIGN 30
2.1 Introduction 30
2.2 Product Design 32
2.3 Process Design 36
2.4 Schedule Design 47
2.5 Facilities Design 63
2.6 Summary 70
References 72
Problems 74
Chapter Three FLOW SYSTEMS, ACTIVITY RELATIONSHIPS,
AND SPACE REQUIREMENTS 83
3.1 Introduction 83
3.2 Flow Systems 84
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Contents
3.3 Material Flow System 88
3.4 Departmental Planning 97
3.5 Activity Relationships 113
3.6 Space Requirements 119
3.7 Summary 129
References 129
Problems 131
Chapter Four PERSONNEL REQUIREMENTS 137
4.1 Introduction 137
4.2 The Employee–Facility Interface 138
4.3 Restrooms 146
4.4 Food Services 151
4.5 Health Services 156
4.6 Barrier-Free Compliance 157
4.7 Office Facility Planning 160
4.8 Summary 170
References 170
Problems 171
Part Two
DEVELOPING ALTERNATIVES:
CONCEPTS AND TECHNIQUES 173
Chapter Five MATERIAL HANDLING 175
5.1 Introduction 175
5.2 Scope and Definitions of Material
Handling 176
5.3 Material Handling Principles 179
5.4 Designing Material Handling Systems 181
5.5 Unit Load Design 186
5.6 Material Handling Equipment 204
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Contents
5.7 Estimating Material Handling Costs 209
5.8 Safety Considerations 210
5.9 Summary 212
References 212
Problems 213
Appendix 5 Material Handling Equipment 215
Chapter Six LAYOUT PLANNING MODELS AND
DESIGN ALGORITHMS 292
6.1 Introduction 292
6.2 Basic Layout Types 294
6.3 Layout Procedures 296
6.4 Algorithmic Approaches 302
6.5 Department Shapes and Mail Aisles 342
6.6 Simulated Annealing and Genetic
Algorithms 344
6.7 Multi-Floor Facility Layout 351
6.8 Commercial Facility Layout Packages 354
6.9 The Impact of Change 355
6.10 Developing Layout Alternatives 362
6.11 Summary 363
References 366
Problems 369
Part Three
FACILITY DESIGN FOR VARIOUS
FACILITIES FUNCTIONS 383
Chapter Seven WAREHOUSE OPERATIONS 385
7.1 Introduction 385
7.2 Missions of a Warehouse 387
7.3 Functions in the Warehouse 389
7.4 Receiving and Shipping Operations 391
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Contents
7.5 Dock Locations 414
7.6 Storage Operations 415
7.7 Order Picking Operations 432
7.8 Summary 443
References 443
Problems 444
Chapter Eight MANUFACTURING SYSTEMS 448
8.1 Introduction 448
8.2 Fixed Automation Systems 451
8.3 Flexible Manufacturing Systems 453
8.4 Single-Stage Multimachine Systems 456
8.5 Reduction in Work-in-Process 458
8.6 Just-in-Time Manufacturing 459
8.7 Facilities Planning Trends 467
8.8 Summary 468
References 469
Problems 470
Chapter Nine FACILITIES SYSTEMS 473
9.1 Introduction 473
9.2 Structural System Performance 474
9.3 Enclosure Systems 477
9.4 Atmospheric Systems 481
9.5 Electrical and Lighting Systems 490
9.6 Life Safety Systems 500
9.7 Sanitation Systems 505
9.8 Building Automation Systems 508
9.9 Facilities Maintenance Management Systems 510
9.10 Summary 510
References 511
Problems 511