Manufacturing

Facilities Design and

Material Handling

FIFTH EDITION

Matthew P. Stephens
Fred E. Meyers

Purdue University Press

West Lafayette, Indiana
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 INFORMATION FOR 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 Information 36
Inventory Policy 36
Lean Thinking and Muda as Part of Management Policy 36
Investment Policy 37

Startup Schedule 37
Make or Buy Decisions 38

Organizational Relationships 39

Feasibility Studies 39
Conclusion 40

Questions 41

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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? 46

2. How Many People Should We Hire ? 47
3. How Much Will Our Product Cost ? 50

4. When Should We Start a

Job, 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? 51

5. 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? 52
6. How Do We Measure Productivity ? 53
7. How Can We Pay Our People forOutstanding Performance? 54
8. How Can We Select the Best Method or Evaluate Cost Reduction

Ideas? 55

9. How Do We Evaluate New Equipment Purchases toJustify Their

Expense? 57
/ 0. How Do We Develop a Personnel Budget ? 57

Techniques of Time Study 57

Predetermined Time Standards Systems 58

Stopwatch Time Study 58

Time Study Procedure and the Step-by-Step Form 62

Rating, Leveling, and Normalizing 71

Allowances 73

Types ofAllowances 73
Methods of Applying Allowances 77

Work Sampling 80
Standard Data 81

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 Procedurefor Preparing a Work Cell Load Chart 94

 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 Procedurefor Developing a Flow Diagram 134
The Operations Chart 135

Step-by-Step Procedurefor Preparing an Operations Chart 135

Flow Process Chart 137

Step-by-Step Procedurefor Preparing a Flow Process Chart 139

Computer-Aided Flow Design and Analysis 139

Conclusion 144

Questions 144

CHAPTER 6 ACTIVITY RELATIONSHIP ANALYSIS 145

Objectives 145

Activity Relationship Diagram 146

Determining the Relationship Code 148

Worksheet 150

Dimensionless Block Diagram 150

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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

160
Ergonomics and the Principles of Motion Economy
Principle 1: Hand Motions 161
Principle 2: Basic Motion Types 165
Principle 3: Location ofParts and Tools 166
4:
Principle Freeing the Hands from as Much Work as Possible 168

Principle 5: Gravity 169

Principle 6: Operator Safety and Health Considerations 169

Space Determination 170

Questions 173

CHAPTER 8 AUXILIARY SERVICES 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 Requirements for a Receiving Department 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

Analysis of ABC Inventory 203

Procedure for Sales

ABC Inventory Layout of a Hand Tool Manufacturing Company's Warehouse 204

Warehouse Space Determination 207
Warehouse Equipment 209
Conclusion 209
 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 Fountains 225

Aisles 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
xviii CONTENTS

CHAPTER 11 MATERIAL HANDLING EQUIPMENT 251

Objectives 251

Receiving and Shipping 252

Receiving and Shipping Docks 252

Dock Equipment 256

Moving Equipment 256

Telescopic Conveyor 261

Weight Scale 263

Systems Required on Receiving and Shipping Docks 263

Stores 264

Storage Units 264

Stores MobileEquipment 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
TowConveyors 295
OverheadTrolley 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

 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
 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

 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