Tompkins Facilities Planning: James A. Tompkins, 3rd edition solution. Facilities Planning 4th edition - Textbooks. Access Facilities Planning 4th Edition solutions now. It took the spotlight in news reports-politicians quickly attempting to distance themselves from state-sanctioned phone solicitation programs involving inmates. At first it seemed nothing more than electionyear candidates seizing an opportunity to grandstand. No doubt some clerk had leaked the complaint within minutes of its filing.
The hotel had requested and received crowd control from the Denver police-two of whom pressed through the reporters to help Boldt and Daphne reach the registration desk. Facts surrounding the private commerce program at Etheredge unfolded.
Our book servers saves in multiple countries, allowing you to get the most less latency time to download days end and other stories Hamilton caught him as he was about to topple into the water and lowered him none too gently to the bank.
He came to the motor launch, pulled out his signal torch, hooded the beam with his hand and shone it inside. Get this from a library! Facilities planning. Employ the fastest and most productive receiving process possible, i. Palletized materials with a single SKU per pallet, floor-stacked loose cases, and backordered merchandise are excellent candidates for crossdocking. Bypass receiving staging and put materials away directly to primary picking locations, essentially replenishing those locations from receiving.
In direct putaway systems, the staging and inspection activities are eliminated, saving the time, space, and labor associated with those operations. Minimize the floor space required for staging by providing storage locations for receiving staging. Prepare shipping from the time the materials are received, thus reducing the area for shipping. Ship materials in larger quantities and preferably in unit loads, i. Ship directly from storage and without the need for staging, having prepared the shipping information prior to picking.
Reduce the number of docks, if possible. For example, can receiving and shipping be modified so that less frequent visits to docks are necessary? This will save more space in and around the receiving and shipping areas. Modify docks to degree docks. Finger docks should be eliminated, if possible. Otherwise, can the largest angle finger docks be used? This will allow shrinking of maneuvering and staging areas inside the receiving and shipping areas.
Eliminate dock levelers by requiring uniform-height carriers for loading and unloading, thus reducing or eliminating dock maintenance costs. Remove dock shelters in favor of a more streamlined dock, if dock shelters exist.
Again, maintenance costs will be reduced or eliminated. This problem should not be assigned if the students have not been exposed to either Monte Carlo simulation or queueing theory.
In Chapter 10, we provide queueing models to address problems of this type. The instructor might want to assign this problem before covering the material in Chapter 10 to motivate the students to learn the material on queueing theory. Answers to Problems at the End of Chapter 7 Based on the material in Chapter 10, we provide the following solution to the dock design problem. The problem reduces to determining the smallest value of c number of docks such that the average time trucks spend in the system W is less than 50 minutes.
Hence, since it is desired that W 2. Therefore, 3 docks are required to ensure that the average amount of time spent waiting and being loaded or unloaded is less than 50 minutes. Answers to Problems at the End of Chapter 7 7. Finger docks, however, require greater inside maneuvering area. Because inside space costs considerably more to construct and maintain than outside space, finger docks should be used as little as possible.
If outside space is sparse, then finger docks should be used, although keeping the angle closer to 90 degrees. If degree finger docks are utilized, the bay width is increased from the width of the truck to about 45 feet. Furthe rmore, the dock width will increase from about the width of Answers to Problems at the End of Chapter 7 the truck to about 40 percent more than the width of the truck. That is, assuming that the old dock width is about 10 feet, then the new dock width would have to be around 14 feet to accommodate a degree finger dock.
Therefore, the dock board may be longer and wider than portable dockboards. The extra length results in a smaller incline between the dock and the carrier. This allows easier and safer handling of hand carts, reduced power drain on electrically powered trucks, and less of a problem with fork and undercarriage fouling on the dockboard.
The greater width allows for safer and more efficient carrier loading and unloading. Permanent, adjustable dockboards also eliminate the safety, pilferage, and alignment problems associated with dockboards.
For these reasons, permanent adjustable dockboards should always be given serious consideration, despite their high installation costs.
In many areas, however, the problem is solved by walking up or down a step to accommodate the difference in carrier and dock height. Because surveys indicate that the campus has scattered receiving docks with minimal carrier visits, it is not justified to invest in expensive dock shelters.
The bookstore docking area, ho wever, may benefit from a dock shelter because more frequent stops are made at this location in delivering and shipping more valuable products. Increases in both width and height of trucks and trailers imply that docks may have to be modified to accept taller and, in many cases, wider trucks and trailers.
Some of the changes can be handled by using permanent adjustable dockboards whose dynamic ranges can accept taller or wider trucks. SKUs with high rankings should be assigned to the most accessible locations.
A distribution illustrating SKUs ranked by popularity and the portion of total picking activity they represent is the ABC or Pareto plot used in intelligent stock assignment planning. Correlated stock assignment planning ranks SKUs by popularity as well as considering the correlations between various items in storage. A small picking zone dedicated to high- density, high-throughput order picking is used for SKUs with high correlations.
For example, liquid products in barrels 55 gallon drums are often stored directly on the floor. In particular, tight-block stacking wastes the least amount of storage space and thus has a high storage space utilization. Pallet racks are mostly used when product mix is high and accessibility to a particular product must be quick for faster order-processing. Pallet flow racks provide good storage space cube utilization and allow products to be processed in first-in, first-out FIFO fashion.
They are very good for dated products with high product mix, but lower volume. Drive-in racks allow large pallet counts product volume of high product mixes to be stored and still obtain good storage space cube utilization. Drive-in racks are best used along the walls of plants or warehouses. Drive-through racks can be used the same as drive-in racks, but they also allow accessing the product from both sides of the rack.
They are thus used for areas in the middle of the plant or the warehouse. It also allows for faster replenishment, but it does lower the storage space cube utilization factor. Storing in cantilever racks provides long, unobstructed storage spans.
They are mostly helpful in sorting self-supporting long stock, such as bar stocks, pipes, and lumber. Portable racks are mostly good for loads open stock , such as pipes, that need to be protected against crushing and other damage.
Portable racks result in flexibility and good space utilization of bulk storage, and are also useful for crushable materials and allow access to materials on all levels. Orders that require picking items, rather than cartons or pallets, use bin racks or shelving systems.
A detailed approach to storage space planning for the different SKUs this warehouse would have to receive, store, and ship is not possible with the data given. However, the information from the shipping and receiving analysis chart and the storage analysis chart can be used to determine the space requirement of the SKUs. As part of the storage space planning, certain inventory parameters would have to be determined.
For example, determining the safety stock and knowing the order quantity are crucial in determining the average quantity to be stored for each of the SKUs. The average quantity to be stored will then help in choosing among dedicated storage, randomized storage, and class-based dedicated storage. The main difference between dedicated storage and randomized storage is it implication for what happens when a storage location becomes empty or available.
In randomized storage, the closest-available-slot is designated as the storage location; retrievals are performed on a first-in, first-out FIFO basis, which provides a uniform stock rotation policy. Dedicated storage locations and class-based dedicated storage locations remain active even after stock has been removed from that location and the location is empty. This is partly due to the fact that the number of openings assigned to an SKU must accommodate its maximum inventory level.
The planned quantity of unit loads to be stored for dedicated storage is thus equal to the sum of the openings required for each SKU. With randomized storage, however, the planned quantity of unit loads to be stored in the system is the number of openings required to store all SKUs. Since typically all SKUs will not be at their maximum inventory levels at the same time, randomized storage will generally require fewer openings than dedicated storage.
As part of the storage space planning, consideration must be given to throughput as well. For example, when using dedicated storage, SKUs should be assigned to storage locations based on the ratio of their activity to the number of openings or slots assigned to Answers to Problems at the End of Chapter 7 the SKU. The SKU having the highest ranking is assigned to the preferred opening, with the lowest-ranking SKU assigned to the least-preferred openings.
Because fast movers are up front and slow movers are in back, throughput is maximized. Therefore, for products B, G, I, and L, the travel distance will be the same no matter where along the main aisle the products are stored. Therefore, products having ratios less than 1.
Therefore, products having ratios greater than 1. The layout shown is typical of an aisle-based system. Products are distributed according to throughput, quantity receipt, and the ratio of receiving to shipping trips. In Chapter 10, we provide guidelines for minimizing travel distances. Maximum no. Layout for the Warehouse: A rectangular block stacking area of feet wide by feet deep, minimum dimensions.
The 30 products will be stacked in 90 side-by-side lanes 30 aisles , with one foot separating each product aisle. This scheme tries to reduce the pick face of the stacks, which increases congestion and the time it takes to empty a deep lane. Addressing those issues requires a more rectangular block stacking area at the expense of cube utilization.
A typical layout is depicted below. Thus, cube utilization and product accessibility are inversely proportional. For example, in block stacking storage scheme, cube utilization increases as lane depth increases. This makes accessing deep product s more difficult. In general, however, layouts b and c are preferred over a because they allow more stock accessibility. Layout c is preferred over layout b because it allows the most accessibility of all layouts.
The disadvantage of layout c is that it uses more aisle space and its overall storage space utilization factor will be slightly less. The overall preference is thus c over b , which are both preferred over a. There are three components in an automatic factory — manufacturing, material handling, and the information system. In terms of manufacturing, some decisive factors to justify automation are: Volume of production.
Economics of scale can be achieved by mass production and the financial benefit can compensate the high capital cost of an automatic factory. Expensive machinery. Some industries, such as semiconductor, require expensive machinery. By automating, these machines can be fully utilized to reduce production cost.
Variability reduction. Manual machining, while still within tolerance, often produce parts with high variability. This variability can be reduced significantly by automation. From a material handling perspective, automation is desirable to reduce cost in time due to savings in labor cost. In addition to cost saving, some product may require careful handling; therefore automation is an alternative to prevent product damage.
In addition, the declining costs of computing and data storage continue to fuel the desire to invest in automation. Machinery for semiconductor production cost dearly and should be fully utilized. Product value is also very high; material-handling automation is needed to avert damage.
Another sector would be continuous flow manufacturing such as chemical products. User interface and training Obsolescence Lack of flexibility Risk of having all eggs in one basket if a disaster should strike the warehouse Answers to Problems at the End of Chapter 8 8. A list that is required for a fully automated cross docking facility with respect to the material handling aspect: Software for warehouse management.
Automatic material transport equipment for moving the materials. For example: conveyors, racks that are designed to accommodate cross docking facility, i. Industrial vehicles for transporting from the dock to storage or storage to dock. This device will allow automated retrieval of loads from truck. This device will allow automated retrieval of loads from dock.
Material handling device used Spacing between workstations buffer size 8. The student may also come up with other types of systems. Instead of using AGVs, conveyors can be used for transporting materials.
When using conveyors, a spine layout can also be implemented. When using a spine layout, there is no more loop around the system. This trend is perpetuated by limited tool magazine size and more importantly; keeping a complete set of tools in a magazine may not be economically feasible since tools are generally expensive.
Tools can be categorized into two types: resident, which reside in a machine permanently and transient, which is shared among machines and kept in central tool storage. Determining how many resident and transient tools is the problem.
This also translates to how to allocate the transient tools among machines and how many transport devices is needed. Given the machining schedule, usually based on order priority, the required tool sequence can be known. Simulation or integer programming can be used to find the optimal solution. In practice, keeping active inventory of all tools in the cell with their size, type, number and location, improving tool forecasts and warnings of tools changes, reducing delays in the system, and improving tool information reliability are the core of a tool management system.
Tools are still separated into resident tools and transient tools; however the proportion of resident tools is considerably higher than in a FMS setting. This can be attributed to the nature of SSMS where part only visit a machine once; thus more resident tools are needed.
This arrangement is more costly; in return it offers more versatility, more machine utilization, easier part scheduling and higher throughput. Answers to Problems at the End of Chapter 8 The handling device needs to be flexible in the sense that it must be able to handle all of the part types produced within the flexible cell.
The WIP storage must also conform to the limitations of the cell and material handling system design. In addition, the manual handling that would normally be involved moving a part from a storage device e. Therefore, each of the rules-of-thumb are satisfied in at least one way. Therefore, a worker may save time to perform the task, thus opening the worker to handling more machines. In addition, the operator will not have to spend time arranging components.
Therefore, at least 4 of the 7 wastes are reduced. Both strive for eliminating or minimize waste, produce only what is demanded, minimize the use of time and space resources, and manufacture in the shortest cycle time possible. Mass production is still the best process to use for high volume, repetitive products.
JIT may also be difficult to Answers to Problems at the End of Chapter 8 implement to very low volume or unique products such as in a job shop environment unless there is flexibility in reordering the machine. Like discrete-part production systems, a continuous production system starts with a batch that is processed; however, the batch is processed in a continuous manner from process to process.
So, the batch size can be determined by the actual demand, and therefore, be thought of as a pull system. By limiting the size of the batch the WIP is naturally limited in the system as well. However, it should be noted that most continuous production systems are used in very large scale production, so reducing batch sizes may reduce the utilization of the system. Response will be based on the paper chosen for review. In a U line balancing problem, the set of assignable task is enlarge by those tasks whose successors have been assigned, therefore U line balancing problem is more complex since now task grouping not only move in forward or backward direction as in a straight line, but it can also move in both directions at the same time.
In practice, rebalancing of the line is done quite often following demand changes. Rebalancing involves adding or removing machine from on the line or changing the standard time bases on new layout configuration; it also involves determining the number of operators required and assigning the machines that each operator tends.
The workers should be cross-trained so they can fix each others mistakes or aide in the quality resolution process. There would be cases of overlap, where the one worker would obstruct the path of another worker.
Answers to Problems at the End of Chapter 8 8. The assignments are as follows: Processes Worker Assigned 1 1, 2, 3, 10 2 4, 5 3 6, 7, 8, 9 In this case each worker is not obstructed by any other worker; therefore, it would be a preferable arrangement compared with that of the solution to Problem 8. A good roof design will also help thermal performance. A membrane layer to prevent water penetration, an insulation layer to assist with thermal comfort, and a vapor check to stop vapor migration are all requirements of a good roof.
The floor should have integral water-proofing and an applied membrane to seal the floor against water migration. The primary purpose of an enclosure system for a manufacturing facility is to keep out undesirables. The CU is approximately 0. Using Equation 9. If there are 2 lamps per luminary, then luminaries are required for the facility. This will allow luminaries to be placed within the facility.
This result changes the coefficient of utilization in Table 9. This result yields luminaries that can be placed within the facility. From Equation 9. The ECR is determined by examining Table 9. Since the ECR changed, this affects the coefficient of utilization slightly. The CU decreases to 0. As in Problem 9. This changes the value of the CU to 0. There are 20 classifications or groups of buildings governed by the UBC. Safety of regular building occupants 2. Safety of firefighters 3.
Salvage of the building 4. The goods and equipment in the building 9. Answers to Problems at the End of Chapter 9 9. Any point on the defined line segment is an optimum location.
Any point in the defined square is an optimum location. Customers in the transportation, communication, and service sectors do have a need for facilities planners. Service facilities such as hospitals, restaurants, athletic facilities, and retail shopping establishments all can and do use facilities planners to optimize the facility layout, handling systems, and facility systems on a continuous basis.
The communications industry uses the world as its facility. Communication networks can be thought of as the handling systems of a communications customer. Due to the rapidly changing technologies found in the communications industry, these networks have to be continuously updated and improved, or new ones have to be created. Also, the equipment and personnel required to run multiple communication networks have to be considered as.
Finally, the facilities required to house a communication hub or hubs must be located and designed, and a facilities planner is the optimal person to do this job. Just like the communications industry, the transportation industry uses the world as its facility. Facilities planners can play an integral role in determining where airports, train terminals, bus depots, truck depots, and shipping docks are located and in designing them to accommodate the traffic that travels through them.
Also, facilities planners can assist in determining the equipment and layout of those facilities as well. Service industries such as retail shopping establishments, restaurants, hospitals, and athletic facilities all use facilities planners to lay out their buildings. Also, retail establishments and restaurants generally have warehouses in which product is stored before it comes to its point of use.
Facilities planners play a large role in the location and design of warehouses of all types. Is there enough space for the equipment to maneuver around the facility? The first task that needs to be accomplished is to determine the site of the library on the campus.
Questions such as do existing structures need to be demolished, do roads need to be rerouted, do possible sites meet federal, state, and local codes need to be asked. Next, a determination of office space, book storage space, storage rack layout, and student study areas must be made so that the structural design of the facility can be created. Also, the power, gas, heat, ventilation, security, plumbing fixtures, and maintenance issues must be settled. Finally, material handling issues such as how to transport supplies and books, how to reshelve books, how to get from floor to floor, the information systems required to keep track of the locations of all of the books, and the personnel who will be required to maintain the library must be resolved.
Facilities planning is never completed for an enterprise. If facilities planners believed this, then numerous enterprises would be doomed to failure. New technologies, different enterprises would be doomed to failure.
New technologies, different packaging methods, better storage methods, and more advanced material handling equipment make the process of updating and continuously improving facilities a must, or else the company will be left behind with antiquated structures, information systems, and storage and material handling mechanisms.
Certain items to look for from this paper are that an architect is more involved with the design of the structure of the facility, the materials that will go into the structure, and the. The facilities planner will be consulted on the above issues, but is more likely to plan the material flow within the facility, how materials will be handled within the facility, how materials will be stores, how materials will be manufactured, the location of storage areas, the location of shipping and receiving docks, the location and types of manufacturing equipment, the types of material handling equipment required in the facility.
Other engineering disciplines apply skills to very specific areas. IE gives an opportunity to work in a variety of businesses. The most distinctive aspect of industrial engineering is the flexibility that it offers.
Industrial engineers figure out how to do things better. They engineer processes and systems that improve quality and productivity. They work to eliminate waste of time, money, materials, energy, and other commodities.
Most important of all, IEs save companies money.
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