Production plant design with applications / by A.İ. Sönmez.

Includes bibliographical references and index.

Contents 1. Introduction To Plant Layout 3 1.1 Introduction 3 1.2 Overall Design of An Enterprise (Plant Design) 3 1.3 Plant Location 11 1.4 Plant Layout 18 1.5 Classical Types of Plant Layout 20 1.6 Why Layout Problems Develop 25 1.7 Classes of Plant Layout Problems 27 18 Objectives of Plant Layout 28 2. General Procedure For Developing A Layout 35 2.1 Introduction 35 2.2 Data Collection and Organization 37 2.2.1 Input P , Q . R . S , T and Activities 39 2 2.2 Production Volume 40 2.2.3 Make Or Buy 42 2.2.4 Parts List 42 2 2 5 The Routing Sheet 43 2.2 6 P-Q (Product-Quantity) Chart 46 2 2 7 Equipment Requirement For Product and Process Type of Layouts48 2.3 Flow of Materials 51 2.3 1 Determining Flow of Material Analysis 52 2.3.2 Charts For Flow of Materials 53 2 3.2.1 Operation Process Chart 54 2.3.2.2 Flow Process Chart 58 2.3 2.3 Multi Product Process Chart 60 2.3.2.4 From To Chart 61 2 3 2.5 Sequence Summary Table 65 2.3 2.6 Load Summary Table 65 2.3 2 7 Reduced Load Summary Table 66 2 4 Other Than Flow Relationship (Activity Relationship) Chart 67 2.5 Combining Flow and Other Than Flow Relationships 70 2.6 Analysis of Material Flow 75 2 6 1 Making The Flow of Material Analysis For " Product Type Of Layout " 75 2 6 2 Analysis of Material Flow For " Lined Up Process Type of Layout " 79 2 6 2 1 From-To Chart Analysis 80 2 6 2.2 Multi Product Process Chart Analysis 84 2 6.2 3 Moment Arm Technique 91 2 6.3 Analysis of Material Flow For " Process Type of Layout " 94 2.6.3.1 Grid Analysis 94 2 6.3.2 Systematic Layout Planning (S L P) 105 2 6 3 3 Computerized Layout Planning; (Aldep, Corelap and Craft ) 110 2.6 3 4 Graph Theory '21 2.7 Space Determinations 129 2.7 1 Calculation Method 129 2.7.2 Converting Method 130 2.7 3 Space Standards 130 2 7 4 Roughed Out Layout 130 2 7 5 Ratio Trend and Projection 130 2 8 Space Relationship Diagram 130 2 9 Selecting The Best Layout 131 2.9.1 Advantages Against Disadvantages 132 2 9 2 Cost Comparision 132 2.9.3 Weighted Factor Analysis 132 2 10 Common Problems In Plant Layout 134 2.10 1 Material Handling 134 2.10 1.1 Material Handling Objectives 134 2.10.1.2 Material Handling Equipment and Containers: 136 2.10.2 Storage 139 2 10 2 1 Storage Equipment: 140 2 10.2.2 Arrangement of Storage 141 2.10 2 2 1 Alphabetical and Numerical Sequence of Storage 141 2 10 2 2 2 Modified Alphabetical and Numerical Sequence : 142 2.10 2 2.3 Storage By Space 143 2 10 2 2 4 Storage By Space With Locator Systems: 144 2.10.2.2 5 Automatic Warehousing: 145 2.10.3 Building Design 146 3. Preparation of Product Type of Layout 155 3.1 Introduction 155 3.2 Input Data 155 3 2 1 Technical Drawings 155 3 2.2 Parts List 155 3 2.3 Make Or Buy Analysis 157 3 2 4 Determination of Volume of Output 159 3 2 5 Production Routing Sheets 160 3 2 6 Standard Time Calculations 162 3.2.7 Machine Requirement Sheets 171 3.3 Material Flow Analysis 171 3 3 1 Operation Process Chart 171 3.3 2 Flow Process Chart 171 3 4 Relationship Diagram 179 3.5 Space Calculations 179 3 6 Spaced Relationship Diagram 183 3.7 Cost Analysis 183 4. Preparation of Lined-Up Process Type of Layout 191 4 1 Introduction 191 4.2 Input Data 191 4.2.1 Technical Drawings 191 4.2.2 Parts List 203 4 2.3 Determination of Volume of Output 204 4.2.4 Production Routing Sheets 205 4.2.5 Machine Requirement Sheets 205 4 2.6 Charts and Tables 205 4.2.6 1 Sequence Summary Table 205 4,2.6.2 From-To Chart 237 4 2 6 3 Multi-Product Process Chart 239 4 2 6.4 Load Summary Table 239 4 2.6.5 Reduced Load Summary Table 239 4.3 Material Flow Analysis 243 43 I From Tochart Analysis 243 4.3.2 Multi-Product Process Chart Analysis 250 4.3.3 Moment Arm Technique 252 4 3 4 Selecting The Best Layout 256 44 Relationship Diagram 258 4.5 Space Calculations 258 4.6 Spaced Relationship Diagram 260 4.7 A Computer Program 262 5. Preparation of Process Type of Layout 273 5.1 Introduction 273 5.2 Input Data 273 5.3 Flow of Material Analysis 275 5.4 Other Than Flow of Material Relationships 276 5 5 Combining Flow and Other Than Flow of Material Relationships 278 5 6 Making 1Ayout For Process Type of Layout 281 5.6.1 Grid Analysis 281 5.6.2 S L P. (Systematic Layout Planning) 288 5.6.3 Aldep and Corelap Layout Techniques 291 5.6.4 Graph Theory 295 5.7 Selecting The Best Layout 301 5 8 Computer Programs 302 6. Overall Results For The Layout of The Prepared Factory 317 6 1 Introduction 317 6.2 Plant Location 317 6 3 Plant Site Design 320 7. Some Analytical Techniques For Plant Design 327 7.1 Introduction 327 7.2 Assembly Line Bali.Ancing Problems 327 7 2.1 J Ackson's Method 330 7 2 2 Helgeson and Bernie (H-B) Solution 333 7 2 3 Comsoal (Computer Method of Sequencing Operations For Assembly Lines) 334 7 3 Transportation Method 344