Part One DEFINING REQUIREMENTS 1 Chapter One INTRODUCTION 3 1.1 Facilities Planning Defined 3 1.2 Significance of Facilities Planning 9 1.3 Objectives of Facilities Planning 12 1.4 Facilities Planning Process 13 1.5 Strategic Facilities Planning 18 1.6 Developing Facilities Planning Strategies 21 1.7 Examples of Inadequate Planning 24 1.8 Summary 26 References 27 Problems 28 Chapter Two PRODUCT, PROCESS, AND SCHEDULE DESIGN 30 2.1 Introduction 30 2.2 Product Design 32 2.3 Process Design 36 2.4 Schedule Design 47 2.5 Facilities Design 63 2.6 Summary 70 References 72 Problems 74 Chapter Three FLOW SYSTEMS, ACTIVITY RELATIONSHIPS, AND SPACE REQUIREMENTS 83 3.1 Introduction 83 3.2 Flow Systems 84 3.3 Material Flow System 88 3.4 Departmental Planning 97 3.5 Activity Relationships 113 3.6 Space Requirements 119 3.7 Summary 129 References 129 Problems 131 Chapter Four PERSONNEL REQUIREMENTS 137 4.1 Introduction 137 4.2 The Employee–Facility Interface 138 4.3 Restrooms 146 4.4 Food Services 151 4.5 Health Services 156 4.6 Barrier-Free Compliance 157 4.7 Office Facility Planning 160 4.8 Summary 170 References 170 Problems 171 Part Two DEVELOPING ALTERNATIVES: CONCEPTS AND TECHNIQUES 173 Chapter Five MATERIAL HANDLING 175 5.1 Introduction 175 5.2 Scope and Definitions of Material Handling 176 5.3 Material Handling Principles 179 5.4 Designing Material Handling Systems 181 5.5 Unit Load Design 186 5.6 Material Handling Equipment 204 5.7 Estimating Material Handling Costs 209 5.8 Safety Considerations 210 5.9 Summary 212 References 212 Problems 213 Appendix 5B Material Handling Equipment 215 Chapter Six LAYOUT PLANNING MODELS AND DESIGN ALGORITHMS 292 6.1 Introduction 292 6.2 Basic Layout Types 294 6.3 Layout Procedures 296 6.4 Algorithmic Approaches 302 6.5 Department Shapes and Mail Aisles 342 6.6 Simulated Annealing and Genetic Algorithms 344 6.7 Multi-Floor Facility Layout 351 6.8 Commercial Facility Layout Packages 354 6.9 The Impact of Change 355 6.10 Developing Layout Alternatives 362 6.11 Summary 363 References 366 Problems 369 Part Three FACILITY DESIGN FOR VARIOUS FACILITIES FUNCTIONS 383 Chapter Seven WAREHOUSE OPERATIONS 385 7.1 Introduction 385 7.2 Missions of a Warehouse 387 7.3 Functions in the Warehouse 389 7.4 Receiving and Shipping Operations 391 7.5 Dock Locations 414 7.6 Storage Operations 415 7.7 Order Picking Operations 432 7.8 Summary 443 References 443 Problems 444 Chapter Eight MANUFACTURING SYSTEMS 448 8.1 Introduction 448 8.2 Fixed Automation Systems 451 8.3 Flexible Manufacturing Systems 453 8.4 Single-Stage Multimachine Systems 456 8.5 Reduction in Work-in-Process 458 8.6 Just-in-Time Manufacturing 459 8.7 Facilities Planning Trends 467 8.8 Summary 468 References 469 Problems 470 Chapter Nine FACILITIES SYSTEMS 473 9.1 Introduction 473 9.2 Structural System Performance 474 9.3 Enclosure Systems 477 9.4 Atmospheric Systems 481 9.5 Electrical and Lighting Systems 490 9.6 Life Safety Systems 500 9.7 Sanitation Systems 505 9.8 Building Automation Systems 508 9.9 Facilities Maintenance Management Systems 510 9.10 Summary 510 References 511 Problems 511 Part Four DEVELOPING ALTERNATIVES: QUANTITATIVE APPROACHES 515 Chapter Ten QUANTITATIVE FACILITIES PLANNING MODELS 517 10.1 Introduction 517 10.2 Facility Location Models 518 10.3 Special Facility Layout Models 569 10.4 Machine Layout Models 577 10.5 Conventional Storage Models 580 10.6 Automated Storage and Retrieval Systems 608 10.7 Order Picking Systems 627 10.8 Fixed-Path Material Handling Models 642 10.9 Waiting Line Models 671 10.10 Simulation Models 701 10.11 Summary 705 References 705 Problems 709 Part Five EVALUATING, SELECTING, PREPARING, PRESENTING, IMPLEMENTING, AND MAINTAINING 743 Chapter Eleven EVALUATING AND SELECTING THE FACILITIES PLAN 745 11.1 Introduction 745 11.2 Evaluating Facilities Plans 748 11.3 Selecting the Facilities Plan 802 11.4 Summary 803 References 803 Problems 804 Chapter Twelve PREPARING, PRESENTING, IMPLEMENTING, AND MAINTAINING THE FACILITIES PLAN 807 12.1 Introduction 807 12.2 Preparing the Facilities Plan 807 12.3 Presenting the Facilities Plan 831 12.4 Implementing the Facilities Plan 834 12.5 Maintaining the Facilities Plan 836 12.6 Summary 839 References 839 Problems 840 INDEX 841

Part 1: Defining Requirements Strategic Facilities Planning Product, Process, and Schedule Design Flow Systems, Activity Relationships, and Space Requirements Personnel Requirements Part 2: Developing Alternatives: Concepts and Techniques Material Handling Layout Planning Models and Design Algorithms Part 3: Developing Alternatives: Functions Warehouse Operations Manufacturing Operations Facilities Systems Part 4: Developing Alternatives: Quantitative Approaches Quantitative Facilities Planning Models Evaluating, Selecting Preparing, Presenting, Implementing, and Maintaining Part 5: Evaluating and Selecting the Facilities Plan Preparing, Presenting, Implementing, and Maintaining Facilities Plans