Facilities Planning and Design: Pearson New International Edition

Alberto Garcia-Diaz / J. MacGregor Smith  
Total pages
November 2013
Related Titles

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Facilities Planning and Design: Pearson New International Edition
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For undergraduate courses in facilities planning and material handling.


Based on ten years' teaching experience, this text takes a practical, teachable approach to facilities planning and design. A class design project centered on a factory incorporates the theoretical aspects of facilities planning and design. Motivating and illustrating mathematical models wherever possible, the text explores facilities planning, capstone design, and even simulation modelling.


A factory project integrates the theoretical aspects of facilities planning and design. This class design project acts as an inter-connector of topics and as a channel for students to gain skills and expertise in such areas as:

- design

- team work

- oral and written communication

- use of engineering fundamentals, computer, and mathematics along with basic areas of industrial engineering to solve real-life problems.


Numerical illustrations clarify the meaning of the formulations and the output from the corresponding solutions. They are provided throughout with the exception of a few advanced topics.


Instructor resources include lecture slides and a Web site offering additional teaching materials. In addition, numerous worked example, homework problems, and the class design factory project make it easier for instructors to teach their courses.



Table of Contents

Fundamental Principles of Facilities Planning and Design


1.1  Introduction

 What is Design

 Characteristics of Design Problems

 Design Program

 Design Process

1.2  Hierarchical Cycle of Facilities Planning

1.3  Objectives of Facilities Planning

  Issue-Based Information Systems

  Site-Planning IBIS Example

  Decision-Support (DSS) Computer Programs

1.4  Mathematical Models in Facility Planning

1.5  Manufacturing Systems Concepts

1.6  Types of Basic Manufacturing Layouts

  Fixed-Position Layout

  Product Layout Process

  Process Layout Process

  Cellular Layout Process

1.7  Service Systems

1.8  Renovation or Reengineered Facilities

1.9  Facilities Planning and Design Constraints

1.10 Summary and Conclusion

1.11 Exercises



Factory Layout and Material Handling Project


2.1 Introduction

2.2 Project Overview

  Computerized Format Files

  Basic Documents

  Project Report

2.3 Section I: Product Analysis

   Production Drawings

   Parts List and Identification System

   Assembly Flowchart

2.4 Section II: Parts Manufacturing

   Route Sheets

   Machine Requirements and Costs

   Machine Requirements

   Machine Costs

   Material Requirements

   Machine Drawings

2.5 Section III: Layouts Planning

   Layout Planning Charts

   Material handling Requirements and Costs

2.6 Section IV: Personnel Planning

   Personnel Requirements and Costs

   Unit Costs

2.7 Section V: Office Layout

2.8 Section VI: Recommended Plant Layout


Product Design and Process Planning


3.1 Market Research

   Types of Market Research

   Qualitative Forecasting Methods

   Quantitative Forecasting Methods

3.2 Product Design

   Product Design Process

   Bill of Materials or part List

   Component Part Drawing

   Assembly Drawing

3.3 Product Design

   Concurrent Engineering

   Quality Function Deployment

Value Analysis

3.4 Factory Design Project: Section I. Product Design

   What Product?

   What Parts Compose the Product?


  Report Organization

3.5 Process Planning

   Process Planning Procedure

   Selection of Manufacturing

   Sequencing of Manufacturing Processes

3.6 Types of Process Planning

   Manual Process Planning

   Variant Process Planning

   Generative Process Planning

   Generative Process Planning (GPP)

   Semigenerative Process Planning

   Computer-Aided Manufacturing

3.7 Schedule

3.8 Factory Design Project: Section II. Process Design


  Organization of Report

3.9 Summary

3.10 Exercises



Layout Planning Procedures


4.1 Introduction

4.2 Systematic Layout Planning

4.3 From-To Program

4.4 Production Flow Analysis

   Overview of Conceptual Approach

Integration of SLP and PFA

4.5 Flow Planning

4.6 Layout Planning Chart

4.7 Space Requirements

4.8 Facility Layout (FLAP)

   Description and Illustration of Procedure

   Facilities layout Program (FLAP): User Instructions

4.9 Summary

4.10 Exercises



Location Models in facility Planning


5.1 Single-Facility Location Model

   Minisum Location Problem with Rectilinear Distances

   Extension to Rectangular Areas

   Minimax Location Model for Single Facility

   Minimax Location Problem for Rectilinear Distances

5.2 Location-Allocation Problem

   Mathematical Model

   Solution Procedure

5.3 Quadratic Assignment Problem (QAP)

5.4 Heuristic Methods for Solving the QAP

   Incremental Cost after adding a new facility

   Pairwise Interchange

   Heuristic Construction Procedure

   Heuristic Improvement Procedure

5.5 Exercises


Computerized Layout Procedures


6.1 Introduction

6.2 Scope and Definitions

6.3 Facility Layout Software Issues

6.4 Exact QAP and GTLN Optimization Procedures

   Exact Graph-Theoretic Procedures

6.5 Heuristic Procedures

   Improvement Procedures

   Improvement Algorithms

   Construction Procedures

6.6 Quadratic Set Packing Models

Problem Statement and Objective

Branch-and-Bound Algorithm

Manufacturing Layout Solution

Factory Project Examples

6.7 STEP Algorithm

   Stochastic Examples


   Sampling test and Pairwise Exchange Procedure

   The Concept of the Sampling Test

   Computational Results

   Factory Project Example

6.8 Summary

6.9 Exercises



Material Handling Principles, Equipment, and System Design


7.1 Introduction


7.2 Scope and Definitions

7.3 Principles of Material Handling (PAS1 S 2AGES)

   Unit Load Principle S2

7.4 Designing Material Handling Systems (MHS)

7.5 Material Handling Equipment


   Monorails, Hoists, and Cranes

   Industrial Trucks

7.6 MHS Decision-Support Tool

   Architecture of the Application

   The Knowledge Base

   Development of Knowledge Base

   Developing the Decision-Support System

   Advantages of DSS

   Two-Step Approach

   Limitations of Existing Expert Systems

   Decision-Support System for Material Handling

   Equipment Selection

   Flow of the Application

   DSS Stage II for Cranes

   Final Synthesis

7.7 Factory Design Project: Section III. Layout Planning and Material Handling

   Layout Planning Chart

   Material Handling Requirements

   Material Handling Costs

   Proposed Layout

   Sample Calculations

   Report Organization

   Initial Layout

   Material handling Requirements and Costs

7.8 Summary and Conclusion

7.9 Exercises



Material Handling Systems Analysis


8.1 Introduction


8.2 Integration of Layout and Material Handling System

   Fundamental Integration Principle

   Case Study

   Addenda to Section III of Project

8.3 Open Network System Design Tool: GQnet

  GQnet Basic Assumptions

   GQnet Algorithm

   GQnet Computational Results

8.4 Closed-Loop Conveyor Systems Overview

   Deterministic Conveyor Model

   Conveyor Example

   Stochastic Analytical Approaches


   Computer Experiments

8.5 Simulation Models


   Cellular Methodology

   Simulation Section Outline

   Background of Case Study

   Individual Cell Simulation Model

   Cell Network Study

8.6 Warehouse Simulation



Problem Description

Layout of factory

8.7 Summary and Conclusions

8.8 Exercises



Storage and Warehouse Systems


9.1 Introduction

9.2 Receiving and shipping

   Receiving and Putaway Operations

   Processing Customer Orders

   Order Picking

   Packing and Shipping

   Cross Docking

9.3 Dedicated and Random Storage

   Dedicated Storage

   Random Storage

9.4 Models for Determining Storage Capacity

   Service-Level Approach

   Cost-Based Approach

9.5 Storage-Capacity Determination

   Randomized Storage Policy

9.6 Dock Planning and Design

   Dock Location

   Types of Docks

   Dock Design

   Dock Levelers

   Dock Safety

9.7 Warehouse Systems Design

   Storage Equipment


   Rack Storage Systems

9.8 Automated Storage and Retrieval Systems (AS/RS)

9.9 Exercises



Site-Planning Design


10.1 Introduction


Example Sitting Problem

10.2 Site-Planning Methodology

  Objective /Attribute Hierarchy

  Basic Assumptions

  First Assumption

  Second Assumption

  Third Assumption

  Fourth Assumption

  Performance Functions

10.3 Site-Selection Criteria

  Physical Criteria

  Cultural Criteria

  Functional Criteria

10.4 Manufacturing Site-Planning Examples

  Objective Function (Distance or Time)

  Site-Planning Example

10.5 Factory Project Case Study



  Views Evaluation

  Site Drainage

  Final Summary Evaluation

  Factory Project Site- Planning Example

10.6 Summary and Conclusions

10.7 Exercises



Office and Personnel Layout Planning


11.1 Introduction


 Outline of Chapter

11.2 Office Spatial Organization Problem

  General Functions of Office

11.3 Office Space Guidelines

Ancillary Space Guidelines

Miscellaneous Areas of Offices

11.4 Personnel Requirements and Office Arrangements

  Personnel Requirements

 Types of Office Arrangements

 Example Office layout

11.5 Utility Company office case Study


Alternative 2

Alternative 3

Alternative 4

Analysis and conclusions

11.6 Factory Design Project: Section IV. Personnel Requirements and Calculation of Product Total Unit Cost

Conceptual Overview

Organization of Report

Positions and Job Descriptions

11.7 Factory Design Project: Section V. Office Layout Planning

  Overall Conceptual Approach

  Report Organization

  Selected Office Layout

11.8 Summary and conclusions

11.9 Exercises



Final Synthesis


12.1 Introduction

Overview of Chapter

Professions Involved in Facilities Planning

Leased Facility for Project

12.2 New vs. Existing Buildings

12.3 Structural Engineering

  Roofs and Floors

  Walls and Columns

   Building-Code Considerations

12.4 Heating, Ventilating and Air-Conditioning (HVAC)



  Vertical Transportation

12.5 Functional Adaptation of Existing Buildings



12.6 Building Economics

  Structural System


  Mechanical Systems

  Administrative Costs


12.7 Factory Design Project: Section VI. Recommended Plant Layout

  Factory Report Organization

  Plant layout Summary Sheet

  Checklist for Final Report

  Breakeven-Point Analysis

  Factory Project Presentation Guidelines


  Appendix: Renovation vs. New Construction Planning Issues