Handbook Factory Planning And Design

512 Pages·2015·18.344 MB·English

by  Hans-Peter Wiendahl, Jürgen Reichardt, Peter Nyhuis

Hans-Peter Wiendahl · Jürgen Reichardt
Peter Nyhuis
Handbook
Factory Planning
and Design
Handbook Factory Planning and Design
StructureoftheBook
Hans-Peter Wiendahl
(cid:129)
Jürgen Reichardt Peter Nyhuis
(cid:129)
Handbook Factory
Planning and Design
123
Hans-Peter Wiendahl Peter Nyhuis
Garbsen IFAInstitut fürFabrikanlagen und
Germany Logistik
Leibniz Universität Hannover
JürgenReichardt Garbsen
Fachbereich Baukonstruktionund Germany
Industriebau
Fachhochschule Münster
Münster
Germany
Translated byRett Rossi
Additionalmaterial tothis bookcan bedownloaded from http://extras.springer.com.
ISBN 978-3-662-46390-1 ISBN 978-3-662-46391-8 (eBook)
DOI 10.1007/978-3-662-46391-8
LibraryofCongressControlNumber:2015933365
SpringerHeidelbergNewYorkDordrechtLondon
©Springer-VerlagBerlinHeidelberg2015
Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeor
part of the material is concerned, specifically the rights of translation, reprinting, reuse of
illustrations,recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,
andtransmissionorinformationstorageandretrieval,electronicadaptation,computersoftware,
orbysimilarordissimilarmethodologynowknownorhereafterdeveloped.
Theuseofgeneraldescriptivenames,registerednames,trademarks,servicemarks,etc.inthis
publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesare
exemptfromtherelevantprotectivelawsandregulationsandthereforefreeforgeneraluse.
Thepublisher,theauthorsandtheeditorsaresafetoassumethattheadviceandinformationin
thisbookarebelievedtobetrueandaccurateatthedateofpublication.Neitherthepublisher
northeauthorsortheeditorsgiveawarranty,expressorimplied,withrespecttothematerial
containedhereinorforanyerrorsoromissionsthatmayhavebeenmade.
Printedonacid-freepaper
Springer-VerlagGmbHBerlinHeidelbergispartofSpringerScience+BusinessMedia
(www.springer.com)
Preface
The 1990s saw the rapid development of both the Internet and business
logistics.Less than twodecadeslater, theglobalized economywas areality.
Nowadays,sustainabilityandresourceefficiencyareguidingprinciplestorun
a factory. The digital communication of orders, processes, and resources is
the next foreseeable development step in manufacturing.
Enterprises now frequently distribute their productions over several sites
in a number of countries, and their productions are usually subject to strong
fluctuations.Individualsitesthus havetobehighlyreactiveandchangeable.
This in turn necessitates a paradigm change; generally speaking, we need to
invert the way we have traditionally considered a factory. Whereas previ-
ously, the primary task of a parent company was seen as developing a
product,producingitandprocessingorders,whileprocuringanddistributing
finished goods to customers were secondary, today’s priority is reliably
supplying globally distributed markets from the most advantageous sites.
Instead of central factories with a broad manufacturing depth, transformable
or even temporary production sites located near the individual markets are
now essential.
With this in mind, we realized that a critical look at factory planning up
until now had to be undertaken. In gathering information from numerous
research projects and industrial-based projects conducted in various bran-
ches,itbecameclearthatinadditiontothecustomaryprimarygoalofbeing
as efficient as possible, additional demands have arisen:
(cid:129) Depending ontheimpulse forchange, afactory needs tobeabletoadjust
itself within a suitable time period with regard to both production tech-
nology and spatial demands on each of the impacted factory levels.
(cid:129) Manufacturingandassemblysystemsneedtotakeintoconsiderationlocal
perspectivesconcerningknow-how,wagecosts,andrequiredvalue-adding
(i.e., local content).
(cid:129) Production facilities and buildings need to be designed so that they con-
serve resources and are energy efficient.
(cid:129) The external appearance of the factory needs to represent the corporate
identity of the enterprise, while the internal appearance needs to meet the
claim of the product.
(cid:129) The spatial design of production sites needs to provide comfortable
workplaces, thereby expressing the company’s high regard for its
employees.
v
vi Preface
Inconsiderationofallthisandoveranumberofyears,wehavedeveloped
the tri-fold structure of this book. It is based on the second edition of the
German “Handbuch Fabrikplanung” (Handbook Factory Planning),
published in 2014 by Hanser Verlag Munich.
Thefirstpartofthebookconsistsoffivechaptersandbeginsbydeveloping
adeeperunderstandingofthedriversbehindfactorychangesandtheresulting
planningbasisincludingfuturedemands.Followingthat,wereviewexisting
productionconceptsandconcludebyderivingvariouscharacteristicsofwhat
werefertoasa‘site’schangeability’.
In the second part of the book, we describe the planning and design
process of a production site from the level of individual workstations to the
level of various sections, up to the levels of the building and location itself.
Dependingonthelevel,wediscussstrategicandfunctionalplanningaspects
as well as aspects pertaining to the actual organization of work—all with a
special emphasis on changeability. Describing the spatial specifications of
theselevelsplaysacentralroleindirectingthefactoryplanner’sviewtothe
notionthatformnotonlyfollowsfunction,butalsofollowstheperformance
of the buildings and the building services they are equipped with.
With three chapters in the third part of the book, we focus on the sys-
tematicfactoryplanningprocesswithrespecttothesenewrequirements.The
center of our discussion is the synergetic factory planning model. In seven
stages, it describes the creative interplay between production planning and
spatial planning based on acontinuous3-D-modelingstarting with thegoal-
setting right up to the ramp-up. The second chapter takes a look at project
management, including the aspects offorming a project team, the responsi-
bilitiesorteamtasks,aswellasabriefoverviewofdigitaltoolsforplanning
a factory. In view of the frequent changes of use, it becomes all the more
importanttoefficientlyuserealestateproperties;thelastchapterofthebook
is therefore dedicated to facility management.
Our goal with this handbook is first and foremost to provide a compre-
hensive,methodical,andpracticalsupportforthemanagementofproduction
enterprises as well as for planners and designers of production sites. The
same applies to architects and construction planners who design and realize
industrial buildings. Moreover, this handbook is also intended for those
studyingproductiontechnologyandindustriallogisticsfromtheperspectives
of both engineering and management, and for architecture and building
construction students.
Before delving into our subject matter, we would like to thank first of all
Mrs.RettRossi,ourmostvaluedtranslator,whowentdeepintothecomplex
subject and delivered a perfect performance. Next to thank is Jens Lübke-
mann from the IFA Institute of Production Systems and Logistics Leibniz
University, Hannover, for coordinating the work between the authors, our
reviewers,andMrs. Rossiaswell asthepreparationofthecorrectformat of
text and figures. Mr. Gerhard Hoffmann, CEO of IFES GmbH in Cologne,
has contributed Sect. 11.3 and Detlef Gerst Chap. 7; to both, we have to
express our sincere thanks. In addition, we are much indebted to Indranil
Bhattacharya, from the architectural firm Reichardt–Maas and Associates
(Essen/Bangalore), for energetically supporting Chaps. 11–14 on spatial
Preface vii
planningespeciallywithregardtoadaptingittointernationalaspectsaswell
as adding British building norms and quoting of English standard literature
sources. Many thanks go further to our colleagues Prof. Hoda and Waguih
ElMaraghy, University of Windsor Canada, and Prof. Neil Duffie, Madison
Wisconsin University, for carefully reviewing several chapters. Last but not
least we would like to thank the members of the Scientific Publishing Ser-
vicesinChennai,Indiafortheexcellentpreparationofthefinalbooklayout.
This concerns mainly Mr. Udhaya Kumar P. and Ms. Shilpa Soundararajan.
Garbsen, March 2015 Hans-Peter Wiendahl
Essen Jürgen Reichardt
Garbsen Peter Nyhuis
Contents
1 Factory Change Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Stagnant Factories . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Previous Methods of Corporate
Management. . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.3 Competitive Factors of Superior
Enterprises . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Planning Basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Production Strategies . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Factory Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Market Offer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Business Processes. . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Aspects of Factory Design . . . . . . . . . . . . . . . . . . . . 21
2.6 Manufacturing Location and Factory . . . . . . . . . . . . . 22
2.7 Morphology of Factory Types. . . . . . . . . . . . . . . . . . 23
2.8 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Production Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Responsiveness. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 Quantity and Variant Flexibility. . . . . . . . . . . . . . . . . 31
3.4 Focusing on Limits . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.5 Self-organization and Participation. . . . . . . . . . . . . . . 40
3.6 Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.7 Networking and Cooperation. . . . . . . . . . . . . . . . . . . 43
3.8 Demographic Development. . . . . . . . . . . . . . . . . . . . 47
3.9 Corporate Culture . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.9.1 Organizational View . . . . . . . . . . . . . . . . . . 48
3.9.2 Architectural View. . . . . . . . . . . . . . . . . . . . 50
3.10 Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.10.1 The Term and Concept. . . . . . . . . . . . . . . . . 52
3.10.2 Consequences for Factory Planning . . . . . . . . 56
3.10.3 Recycling Economy. . . . . . . . . . . . . . . . . . . 58
ix
x Contents
3.11 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4 Known Production Concepts . . . . . . . . . . . . . . . . . . . . . . . 63
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.2 F.W. Taylor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.3 Group Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.4 Manufacturing Cells. . . . . . . . . . . . . . . . . . . . . . . . . 67
4.5 Flexible Manufacturing Systems . . . . . . . . . . . . . . . . 69
4.6 Manufacturing Segments . . . . . . . . . . . . . . . . . . . . . 69
4.7 Lean Production and the Toyota Production
System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.8 Just-in-Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.9 Fractal Enterprises. . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.10 Agility Oriented Competition . . . . . . . . . . . . . . . . . . 78
4.11 Mass Customization. . . . . . . . . . . . . . . . . . . . . . . . . 80
4.12 Production Stages Concept . . . . . . . . . . . . . . . . . . . . 81
4.13 Research Approaches. . . . . . . . . . . . . . . . . . . . . . . . 84
4.14 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5 Systematics of Changeability . . . . . . . . . . . . . . . . . . . . . . . 91
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.2 Flexibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.3 Reconfigurability. . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.4 Changeability and Change Enablers. . . . . . . . . . . . . . 96
5.5 Aspects of Designing Changeability. . . . . . . . . . . . . . 102
5.6 Morphology of Changeability . . . . . . . . . . . . . . . . . . 103
5.7 Classes of Changeability for Production
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.8 Evaluating Changeability . . . . . . . . . . . . . . . . . . . . . 109
5.9 Vision of the Changeable Factory . . . . . . . . . . . . . . . 114
5.10 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6 Functional Design of Workplaces. . . . . . . . . . . . . . . . . . . . 119
6.1 Design Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.2 Production Technology. . . . . . . . . . . . . . . . . . . . . . . 122
6.2.1 Manufacturing Processes. . . . . . . . . . . . . . . . 122
6.2.2 Assembly Methods . . . . . . . . . . . . . . . . . . . 126
6.2.3 Logistic Processes . . . . . . . . . . . . . . . . . . . . 132
6.3 Facilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.3.1 Manufacturing Facilities. . . . . . . . . . . . . . . . 141
6.3.2 Assembly Systems. . . . . . . . . . . . . . . . . . . . 149
6.3.3 Logistical Resources . . . . . . . . . . . . . . . . . . 158
6.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166