制造设施设计和物料搬运 第2版PDF电子书下载

THE IMPORTANCE OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING 1

CHAPTER 1 Introduction to Manufacturing Facilities Design and Material Handling 1

LEAN THINKING AND LEAN MANUFACTURING 4

THE GOALS OF MANUFACTURING FACILITIES DESIGN AND MATERIAL HANDLING 4

THE MANUFACTURING FACILITIES DESIGN PROCEDURE 9

TYPES AND SOURCES OF MANUFACTURING FACILITIES DESIGN PROJECTS 11

COMPUTERS AND SIMULATION IN MANUFACTURING FACILITIES DESIGN 12

ISO 9000 and Facilities Planning 13

GLOSSARY OF MAJOR TERMS 14

QUESTIONS 16

CHAPTER 2 Sources of lnformation for Manufacturing Facilities Design 18

THE MARKETING DEPARTMENT 19

THE PRODUCT DESIGN DEPARTMENT 21

Inventory Policy 28

Lean Thinking and Muda as a Part of Management Policy 28

MANAGEMENT POLICY INFORMATION 28

Investment Policy 29

Starmp Schedule 29

Make or Buy Decisions 30

Organizational Relationships 30

Feasibility Studies 31

CONCLUSION 32

QUESTIONS 33

WHAT IS A TIME STANDARD? 34

CHAPTER 3 Time Study 34

IMPORTANCE AND USES OF TIME STUDY 37

1. How Many Machines Do We Need? 38

2. How Many People Should We Hire? 39

3. How Much Will Our Product Cost? 41

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? 43

5. Determine the Assembly Line Balance, Determine the Conveyor Belt Speed, Load the Work Cells with the Correct Amount of Work,and Balance the Work Cells? 44

6. How Do We Measure Productivity? 44

8. How Can We Select the Best Method or Evaluate Cost Reduction Ideas? 46

7. How Can We Pay Our People for Outstanding Performance? 46

9. How Do You Evaluate New Equipment Purchases to Justify Their Expense? 48

TECHNIQUES OF TIME STUDY 48

10. How Do We Develop a Personnel Budget? 49

Predetermined Time Standards Systems 49

Stopwatch Time Study 52

Time Study Procedure and the Step-by-Step Form 52

Principles of Elemental Breakdown 57

Rating, Leveling, and Normalizing 61

ALLOWANCES 65

Types of Allowances 65

Methods of Applying Allowances 68

Work Sampling 71

Standard Data 72

Expert Opinion Time Standards and Historical Data 72

TIME STANDARDS FOR MANUFACTURING FACILITIES DESIGN 74

QUESTIONS 75

CHAPTER 4 Process Design 76

Route Sheets 77

FABRICATION: MAKING THE INDIVIDUAL PARTS 77

The Number of Machines Needed 80

WORK CELL LOAD CHART 82

Step-by-Step Procedure for Preparing a Work Cell Load Chart 86

ASSEMBLY AND PACKOUT PROCESS ANALYSIS 86

The Assembly Chart 87

Time Standards Are Required for Every Task 87

Paint Conveyor Speed 88

Plant Rate and Conveyor Speed 88

Assembly Line Balancing 90

STEP-BY-STEP PROCEDURE FOR COMPLETING THE ASSEMBLY LINE BALANCING FORM 94

CALCULATING THE EFFICIENCY OF THE ASSEMBLY LINE 100

Use of Computer Simulation 101

LAYOUT ORIENTATION 104

QUESTIONS 104

CHAPTER 5 Flow Analysis Techniques 106

FABRICATION OF INDIVIDUAL PARTS 109

String Diagram 110

Multi-Column Process Chart 112

From-To Chart 113

Process Chart 117

Step-by-Step Description for the Process Chart 117

TOTAL PLANT FLOW 121

Flow Diagrams 121

The Operations Chart 124

Step-by-Step Procedure for Developing a Flow Diagram 124

Step-by-Step Procedures for Preparing an Operations Chart 126

Flow Process Chart 130

Step-by-Step Procedure for Preparing a Flow Process Chart 130

COMPUTER-AIDED FLOW DESIGN AND ANALYSIS 130

CONCLUSION 133

QUESTIONS 133

CHAPTER 6 Activity Relationship Analysis 137

THE ACTIVITY RELATIONSHIP DIAGRAM 138

Determining the Relationship Code 140

WORKSHEET 141

DIMENSIONLESS BLOCK DIAGRAM 142

FLOW ANALYSIS 144

COMPUTER-GENERATED ACTIVITY RELATIONSHIP CHART 146

QUESTIONS 150

CHAPTER 7 Ergonomics and Workstation Design Space Requirement 152

WORKSTATION DESIGN 152

ERGONOMICS AND THE PRINCIPLES OF MOTION ECONOMY 158

Principle 1: Hand Motions 159

Principle 2: Basic Motion Types 160

Principle 3: Location of Parts and Tools 160

Principle 4: Free the Hands from as Much Work as Possible 160

Principle 5: Use Gravity 163

Principle 6: Operator Safety and Health Considerations 165

SPACE DETERMINATION 165

QUESTIONS 169

The Advantages and Disadvantages of Centralized Receiving and Shipping 170

CHAPTER 8 Auxiliary Services Requirement Space 170

RECEIVING AND SHIPPING 170

The Trucking Industry s Effect on Shipping and Receiving 171

The Functions of a Receiving Department 171

Facilities Required for Receiving Departments 173

Space Requirements for the Receiving Department 175

The Functions of a Shipping Department 176

Space Requirements for Shipping Departments 179

STORAGE 180

Just-in-Time Inventories 182

Maximizing the Use of the Cubic Space 182

Provide Immediate Access to Everything 184

Provide Safekeeping 191

WAREHOUSING 192

Warehouse Design Criteria 193

The Functions of a Warehouse 194

Procedure for Sales Analysis of ABC Inventory 196

ABC Inventory Layout of a Hand Tool Manufacturing Company s Warehouse 198

Warehouse Space Determination 200

Warehouse Equipment 201

Conclusion 203

MAINTENANCE AND TOOL ROOM 203

UTILITIES 204

QUESTIONS 205

CHAPTER 9 Employee Services—Space Requirements 207

PARKING LOTS 208

EMPLOYEE ENTRANCES 209

LOCKER ROOMS 211

TOILETS AND RESTROOMS 212

LUNCH ROOMS 215

RECREATION 217

DRINKING FOUNTAINS 218

AISLES 218

MEDICAL FACILITIES 219

MISCELLANEOUS EMPLOYEE SERVICES 220

BREAK AREAS AND LOUNGES 220

QUESTIONS 222

CHAPTER 10 Material Handling 223

COST JUSTIFICATION 224

Sample Material Handling Cost Problem 224

GOALS OF MATERIAL HANDLING 225

THE 20 PRINCIPLES OF MATERIAL HANDLING 226

1. The Planning Principle 226

2. The Systems Principle 227

3. The Material Flow Principle 228

4. The Work Simplification Principle 228

5. Use Gravity 229

6. Maximize the Building Code 229

7. Unit Size Principle 230

8. Mechanization Principle 231

9. Automation Principle 231

10. Equipment Selection Principle 231

11. The Standardization Principle 233

12. The Adaptability Principle 234

13. The Dead Weight Principle 234

14. The Utilization Principle 234

15. The Maintenance Principle 234

16. The Obsolescence Principle 235

17. The Control Principle 235

18. The Capacity Principle 235

20. The Safety Principle 236

19. The Performance Principle 236

THE MATERIAL HANDLING PROBLEM-SOLVING PROCEDURE 237

MATERIAL HANDLING CHECKLIST 238

QUESTIONS 241

CHAPTER 11 Material Handling Equipment 243

RECEIVING AND SHIPPING 244

Receiving and Shipping Docks 244

Dock Equipment 246

Fork Trucks 250

Moving Equipment 250

Telescopic Conveyor 256

Bridge Cranes 256

Weight Scale 257

Systems Required on Shipping and Receiving Docks 257

STORES 260

Storage Units 260

Stores Mobile Equipment 262

Systems Required for Stores Department 267

Tubs and Baskets 269

FABRICATION 269

Shop Containers 269

Workstation Material Handling Devices 273

Manipulators and Lifting Devices 273

Mobile Fabrication Equipment 284

ASSEMBLY AND PAINT 289

Belt Conveyors 291

Slat Conveyor 292

Powered Roller Conveyor 292

Car-Type Conveyor 292

Tow Conveyor 294

Overhead Trolley Conveyor 294

Power and Free Conveyor 295

PACKOUT 298

Box Formers 298

Automatic Taping, Gluing, and Stapling 298

Palletizers 298

Pick and Place Robots 300

Banding 300

Stretch Wrap 300

WAREHOUSING 302

Picking Carts 302

Gravity Flow Bins 303

Tractor-Trailer Picking Cart 303

Rotary Conveyor Bins 305

Clamp Trucks 305

Vertical Warehouse and Picking Cars 307

Packing Station 307

Shipping Containers 308

BULK MATERIAL HANDLING 309

Bulk Material Conveyors 310

COMPUTER-INTEGRATED MATERIAL HANDLING SYSTEMS 313

Cross-Docking and Flow-Through 314

QUESTIONS 316

CHAPTER 12 Office Layout Techniques and Space Requirements 317

GOALS OF OFFICE LAYOUT DESIGN 317

TYPES OF OFFICE SPACE 318

Supervisors Offices 319

Open Office Space 320

Conventional Offices 322

The Modem Office 323

SPECIAL REQUIREMENTS AND CONSIDERATIONS OF SOME OFFICES 325

THE TECHNIQUES OF OFFICE LAYOUT 329

The Organizational Chart 330

Flowchart 331

Communications Force Diagram 332

Activity Relationship Diagram 335

Activity Worksheet 335

Dimensionless Block Diagram 336

Office Space Determination 338

Detailed Master Layout 339

QUESTIONS 341

CHAPTER 13 Area Allocation 342

SPACE REQUIREMENTS PLANNING: STEP ONE 342

BUILDING SIZE DETERMINATION 345

DIMENSIONLESS BLOCK DIAGRAM 345

AREA ALLOCATION PROCEDURE 345

OFFICE AREA ALLOCATION 347

QUESTIONS 351

PLOT PLAN 352

CHAPTER 14 Facilities Design—The Layout 352

Plant Layout Methods 355

MASTER PLAN 355

Advanced Computer Systems 361

PLANT LAYOUT PROCEDURE—TOOLBOX PLANT 366

Office Layout for Toolbox Plant 368

EVALUATION 368

QUESTIONS 373

INTRODUCTION 374

CHAPTER 15 Application of Computer Simulation and Modeling 374

DEFINING COMPUTER SIMULATION 375

ADVANTAGES AND DISADVANTAGES OF SIMULATION 376

SIMULATION IN FACILITIES PLANNING 376

HOW SIMULATION WORKS 377

AN OVERVIEW OF LAYOUT AND SIMULATION SOFTWARE 379

COMPUTER-AIDED LAYOUT DESIGN 379

Computer-Assisted Layout Performance Analysis 381

Simulation in Manufacturing 386

CASE STUDIES 386

Waste Handling and Simulation 387

Simulation and Health Care 387

QUESTIONS 388

CHAPTER 16 Selling the Layout 389

THE PROJECT REPORT 389

THE PRESENTATION 392

ADJUSTMENTS 392

APPROVAL 392

Sourcing 393

THE REST OF THE PROJECT 393

Installation 394

Engineering Plot 394

Production Start 394

Debugging and Follow-Up 395

Conclusion 395

Answers 397

Index 411