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Contents Preface xi CHAPTER 1 Introduction 1 1.1 Nature and Scope of Part I 1.2 Nature and Scope of Part II 1.3 The Role of a Facility Planner 1.4 Computer Programs Suggested Readings PART 1 Planning and Design CHAPTER 2 Product Development 2.1 Market Research 2.2 Quality Function Deployment (QFD) 2.3 Forecasting 2.4 Design 2.5 Design for Manufacture 2.6 Drawings 2.7 Economic Evaluation of Processes 2.8 Computer-Aided Design Summary Problems Suggested Readings CHAPTER 3 Automation 3.1 Sensing Methods 3.2 Bar Codes 3.3 Radio Frequency Identification System 3.4 Machine Vision 3.5 Voice Input 3.6 Programmable Logic Controllers 3.7 Numerically Controlled Machines 3.8 Industrial Robots Summary Problems Suggested Readings CHAPTER 4 Production Charts and Systems 4.1 Production Charts 4.2 Production Systems 4.3 Cell Formation in Group Technology 4.4 Labor Assignments 4.5 Computer Program Description Summary Problems Suggested Readings CHAPTER 5 Requirements and Selection of Machines and Labor 5.1 Machine Selection 5.2 Labor Requirement and Selection 5.3 Machine Coupling 5.4 Total Personnel Requirement Summary Problems Suggested Readings CHAPTER 6 Lean Manufacturing and Supply Chain Lean Manufacturing 6.1 5 S system 6.2 Six Sigma 6.3 Kaizen Philosophy 6.4 Andon 6.5 Takt Time 6.6 Single Minute Exchange of Die (SMED) 6.7 Value Stream Mapping 6.8 Kanban 6.9 Total Production Maintenance(TPM) 6.10 Visual Management 6.11 Multi Skill Workers 6.12 A case study in Lean 6.13 Toyota Production System (TPS) Supply Chain 6.13 Distribution Problem 6.14 Aggregate Planning Model 6.15 Just In-time Production / Pick ups CHAPTER 7 Building, Organization, Communications, and Selected Support Requirements 7.1 Building 7.2 Organization 7.3 Communications 7.4 Support Facilities and Requirements Summary Problems Suggested Readings CHAPTER 8 Material Handling: Principles and Equipment Description 8.1 Definition of Material Handling 8.2 Objectives of Material Handling 8.3 Material-Handling Equipment Types 8.4 Degrees of Mechanization 8.5 The Unit Load Concept 8.6 Principles of Material Handling 8.7 Material-Handling Cost 8.8 Relationship between Material Handling and Plant Layout 8.9 Material-Handling System Design 8.10 Dilemma of an Analyzer 8.11 Specifications of the Design 8.12 Analyzing an Existing Material-Handling System 8.13 Productivity Ratios 8.14 Equipment Used for Material Handling Summary Problems Suggested Readings CHAPTER 9 Material Handling: Equipment Selection 9.1 Basics of Equipment Selection 9.2 Robots in Material Handling 9.3 Automated Guided Vehicle (AGV) in Material Handling 9.4 A Simulation of an AGV Material-Handling System Summary Problems Suggested Readings CHAPTER 10 Material Handling: Flow Lines, Grouping, and Packaging 10.1 Flow Pattern in Assembly Lines 10.2 Machine Grouping in Cellular Manufacturing with Reduction of Material Handling as the Objective 10.3 Machine Placement in Job Shop or Cellular Manufacturing 10.4 Packaging 10.5 Reducing Packaging Costs 10.6 Designing a Packaging Area 10.7 Computer Program Description Summary Problems Suggested Readings CHAPTER 11 Storage and Warehousing 11.1 Warehouse Ownership 11.2 Storage/Warehouse Location 11.3 Building 11.4 Material Requirement Planning (MRP) 11.5 Storage/Warehouse Functions 11.6 Storage and Warehouse Operations 11.7 Accessories 11.8 Stock Location 11.9 Automated Storage and Retrieval 11.10 Loading Docks 11.11 Dock Doors 11.12 Computer Program Description Summary Problems Suggested Readings CHAPTER 12 Plant and Office Layout: Conventional Approach 12.1 Procedure 12.2 Detailed Layout 12.3 Materials Used in Plant Layout Illustrations 12.4 Developing and Analyzing Plant Layouts 12.5 Presenting the Layout 12.6 Office Layout 12.7 Office Landscaping 12.8 Plot Planning 12.9 Evaluating and Implementing the Layout 12.10 Planning Activities 12.11 Computer Program Description Summary Problems Suggested Readings CHAPTER 13 Computer-Aided Plant Layout 13.1 Characteristics of the Problem 13.2 Data Requirements 13.3 Approaches and Types of Procedures 13.4 Mathematical Programming 13.5 Heuristics 13.6 Probabilistic Approaches 13.7 Graph Theory 13.8 Facility Design 13.9 Comments 13.10 Departmental and Layout Shapes 13.11 Scale Effect 13.12 Selection Procedures 13.13 Placement 13.14 Criticisms Concerning Computer-Aided Plant Layout 13.15 Recent Plant Layout Softwares Summary Problems Suggested Readings CHAPTER 14 Simultaneous Development of Plant Layout and Material Handling 14.1 An Algorithm for MH Equipment Selection 14.2 Illustrative Example 1 14.3 An Iterative Process for Layout and Optimum MH Development 14.4 Illustrative Example 2 14.5 Comparison of the Analytical and Heuristic Approaches for Material-Handling System Development 14.6 Computer Program Description Summary Problems Suggested Readings CHAPTER 15 Plant Site Selection and Service (Support) Considerations 15.1 Plant Site Selection 15.2 Utilities Specifications 15.3 Insurance 15.4 Safety 15.5 Americans with Disabilities Act of 1990 15.6 Taxes 15.7 Financial Statements 15.8 Computer Program Description Summary Problems Suggested Readings CHAPTER 16 Computer-Integrated Manufacturing Systems 16.1 Systems and Files 16.2 Components of CIMS 16.3 Benefits and Deficiencies of CIMS 16.4 Planning for CIMS 16.5 System Providers Problems Suggested Readings PART II Facility Location CHAPTER 17 Basic Facility Location Problems 17.1 Single-Facility Placement Problem 17.2 Multiple-Facility Placement Problem 17.3 Brute Force Approach 17.4 Heuristic Method for Problems Involving Facilities with Unlimited Capacities 17.5 Other Methods 17.6 Computer Program Description Summary Problems CHAPTER 18 Location Analysis with Fixed Costs 18.1 Heuristic Method for Solving Problems with Fixed Costs 18.2 Application 18.3 Unassignable Location 18.4 Computer Program Description Summary Problems Suggested Readings CHAPTER 19 Continuous Facility Location 19.1 Single-Facility Locations 19.2 Multiple Facilities 19.3 Multiple Facilities of the Same Type 19.4 Computer Program Description Summary Problems Suggested Readings APPENDIX A Engineering Economy Formulas APPENDIX B Quality Assurance Manual, Spring Controls, Inc APPENDIX C Queuing Results APPENDIX D Mathematical Formulation for Material Equipment Selection (Chapter 14) APPENDIX E Samples of Americans with Disabilities Act of 1990 Checklists APPENDIX F Case Studies APPENDIX G Manufacturing Facilities: Computer Programs Index
Library of Congress Subject Headings for this publication:
Factories -- Design and construction.
Factories -- Location.