Facilities Planning, 4th Editio - Tompkins, James A_.pdf

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Facilities
Planning
TOMPKINS
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WHITE
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BOZER
FOURTH EDITION
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TA N C H O C O
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FACILITIES
PLANNING
FOURTH EDITION
JAMES A. TOMPKINS
Tompkins Associates, Inc.
JOHN A. WHITE
University of Arkansas
YAVUZ A. BOZER
University of Michigan
J. M. A. TANCHOCO
Purdue University
JOHN WILEY & SONS, INC.
V.P. AND EXECUTIVE PUBLISHER Don Fowley
ACQUISITION EDITOR Jenny Welter
EDITORIAL ASSISTANT Alexandra Spicehandler
MARKETING MANAGER Christopher Ruel
DESIGN DIRECTOR Harry Nolan
SENIOR DESIGNER Kevin Murphy
COVER PHOTOS (center) Walter Hodges/Getty Images, Inc.; (top right inset) EIGHTFISH/Getty
Images, Inc.; (center right inset) Courtesy of Tompkins Associates, Inc.; (bottom right inset) Matthew
Rambo/iStockphoto
PRODUCTION MANAGEMENT SERVICES Suzanne Ingrao/Ingrao Associates
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Copyright © 2010
John Wiley & Sons, Inc. All rights reserved.
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ISBN: 978-0-470-44404-7
Printed in the United States of America
10 9 8 7 6 5 4 3 2 1
PREFACE
The fourth edition of
Facilities Planning
is a comprehensive up-to-date text on the
art and science of planning facilities. The purpose of this book is to continue the
creativity, rigor, and design aspects of facilities planning while rejecting the cook-
book and checklist approaches to this discipline.
Because it impacts so many activities and has such a major impact on the suc-
cess of the functions within the facilities, the importance of facilities planning will
continue to grow and challenge the engineering professional. The role of facilities
in the context of the dynamic global supply chain continues to make it very impor-
tant for new professionals to have a depth of understanding of facilities planning.
In this fourth edition, we have reexamined the role of facilities planning
within the supply chain. It is now imperative that the facilities planner assist his or
her company in progressing through the six levels of supply chain excellence:
Business as Usual, Link Excellence, Visibility, Collaboration, Synthesis, and Velocity.
Successful enterprises know that there is no more “business as usual.” Facilities
planning is no longer just the task of planning facilities but a strategy for navigat-
ing a competitive global economy. Every entity must insist on facilities that support
the success of the business both short and long form. We also examine how lean
manufacturing has impacted facilities planning, and in particular, we stress the impor-
tance of developing a Future State Map in defining the departments that constitute
the facility.
In this edition, we endeavor to continue the engineering design process and
application of quantitative tools as a foundation for executing appropriate and suc-
cessful facilities planning. We have given more detailed real-world examples and
problems concerning current facilities planning practices and deleted dated material.
We have added new photography of the industry’s latest material handling equipment
and updated the drawing and diagrams to better reflect the practices taking place
today. The instructor will find improved problem sets, including more quantitative
problems, and a greater variety of helpful questions.
The text is organized as follows:
Defining Requirements
— Strategic Facilities Planning
— Product, Process, and Schedule Design
— Flow Systems, Activity Relationships, and Space Requirements
— Personnel Requirements
Developing Alternatives: Concepts and Techniques
— Material Handling
— Layout Planning Models and Design Algorithms
Developing Alternatives: Functions
— Warehouse Operations
— Manufacturing Operations
— Facilities Systems
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