Handbook Factory Planning And Design

Preface
Contents
About the Authors
1 Factory Change Drivers
1.1 Introduction
1.1.1 Stagnant Factories
1.1.2 Previous Methods of Corporate Management
1.1.3 Competitive Factors of Superior Enterprises
1.1.4 Summary
Bibliography
2 Planning Basis
2.1 Production Strategies
2.2 Factory Strategies
2.3 Market Offer
2.4 Business Processes
2.5 Aspects of Factory Design
2.6 Manufacturing Location and Factory
2.7 Morphology of Factory Types
2.8 Summary
Bibliography
3 Production Requirements
3.1 Introduction
3.2 Responsiveness
3.3 Quantity and Variant Flexibility
3.4 Focusing on Limits
3.5 Self-organization and Participation
3.6 Communication
3.7 Networking and Cooperation
3.8 Demographic Development
3.9 Corporate Culture
3.9.1 Organizational View
3.9.2 Architectural View
3.10 Sustainability
3.10.1 The Term and Concept
3.10.2 Consequences for Factory Planning
3.10.3 Recycling Economy
3.11 Summary
Bibliography
4 Known Production Concepts
4.1 Introduction
4.2 F.W. Taylor
4.3 Group Work
4.4 Manufacturing Cells
4.5 Flexible Manufacturing Systems
4.6 Manufacturing Segments
4.7 Lean Production and the Toyota Production System
4.8 Just-in-Time
4.9 Fractal Enterprises
4.10 Agility Oriented Competition
4.11 Mass Customization
4.12 Production Stages Concept
4.13 Research Approaches
4.14 Summary
Bibliography
5 Systematics of Changeability
5.1 Introduction
5.2 Flexibility
5.3 Reconfigurability
5.4 Changeability and Change Enablers
5.5 Aspects of Designing Changeability
5.6 Morphology of Changeability
5.7 Classes of Changeability for Production Performance
5.8 Evaluating Changeability
5.9 Vision of the Changeable Factory
5.10 Summary
Bibliography
6 Functional Design of Workplaces
6.1 Design Aspects
6.2 Production Technology
6.2.1 Manufacturing Processes
6.2.2 Assembly Methods
6.2.3 Logistic Processes
6.3 Facilities
6.3.1 Manufacturing Facilities
6.3.2 Assembly Systems
6.3.3 Logistical Resources
6.4 Summary
Bibliography
7 Designing Workplaces from a Work Organizational Perspective by Detlef Gerst
7.1 Human Resources as a Concept
7.2 Human Resources and Production Performance
7.3 Competency and Human Resources Development
7.3.1 Professional Competence
7.3.2 Strategies for Developing Competence
7.3.3 Human Resources Development
7.4 Work Structuring
7.5 Motivation
7.6 Designing Remuneration Systems
7.7 Planning Working Times
7.8 Influence of Demographic Change
7.9 Summary
Bibliography
8 Spatial Workplace Design
8.1 Ergonomics
8.2 Room Interiors
8.3 Color Design
8.3.1 Psychological Impact of Color
8.3.2 Safety Colors and Identification of Media Lines
8.3.3 Holistic Color Schemes
8.4 Occupational Health and Safety Standards
8.4.1 Overview
8.4.2 Workplace Regulations
8.4.3 Participation
8.4.4 Tread Certainty and Protection Against Fall
8.4.5 Protection from Hazardous Substances
8.4.6 Noise Protection and Reduction
8.4.7 Protection from Thermal Radiation and Vibrations
8.4.8 Electrical Safety and Protection from Radiation
8.5 Summary
Bibliography
9 Functional Design of Work Areas
9.1 Overview of Design Aspects
9.2 Customer Order Decoupling Point
9.3 Approaches to Handling Orders
9.4 Order Types
9.5 Process Models
9.5.1 Procurement Models
9.5.2 Production Models
9.5.3 Delivery Models
9.6 Manufacturing and Assembly Principles
9.7 Production Segments
9.8 Production Planning and Control
9.9 Selecting and Configuring a Production Control Method
9.10 Summary
Bibliography
10 Spatial Workspace Design
10.1 Communication
10.1.1 Corridors, Stairwells, Intermediary Spaces
10.1.2 Arranging and Linking Workspaces
10.1.3 Location, Shape and Furnishings of Common Areas
10.2 Lighting
10.2.1 Daylight
10.2.2 Natural Lighting
10.2.3 Artificial Lighting
10.2.4 Redirecting Light
10.3 Comfort
10.4 Relaxation
10.4.1 Break-Out Areas and Social Rooms
10.4.2 Canteen, Cafeteria, Coffee Corners
10.4.3 Sport, Recreation and Spare Time
10.5 Fire Protection
10.5.1 Fire Protection Concept and Fire Compartment
10.5.2 Clearances, Firewalls and Complex Separation Walls
10.5.3 Fire Resistance Rating Classes
10.5.4 Evacuation and Rescue Routes
10.5.5 Smoke and Heat Ducts, Fire Extinguishing Equipment
10.6 Summary
Bibliography
11 Building Design
11.1 Load-Bearing Structure
11.1.1 Project Requirements and Load Assumption
11.1.2 Building Structure Form as a Static System
11.1.3 Span Width
11.1.4 Selecting the Materials and Joining Principle
11.1.5 Profiling Support Columns, Beams and Ceiling Slabs
11.2 Shells
11.2.1 Protective Functions
11.2.2 Production and Logistics
11.2.3 Lighting, Views, Communication
11.2.4 Ecology and Energy Production
11.3 Building Services
11.3.1 Supply and Removal Systems
11.3.2 Technical Centers
11.3.3 Main Routings
11.3.4 Line Nets
11.3.5 Inlets and Outlets
11.3.6 Building Services
11.3.6.1 Introduction
11.3.6.2 Requirements
11.3.6.3 Heating Systems
11.3.6.4 Air Conditioning Systems
Overview
Types of Air Flow
Designs
11.4 Interior Finishing
11.4.1 Floors
11.4.2 Walls
11.4.3 Ceilings
11.4.4 Cores
11.4.5 Stairs
11.5 Examples of Changeable Buildings
11.6 Grace and Aesthetics
11.6.1 Structural Order
11.6.2 Simplicity
11.6.3 Balance Between Unity and Diversity
11.6.4 Distinctiveness
11.6.5 Emotional Quality, Atmosphere
11.7 Summary
Bibliography
12 Master Building Plan
12.1 Request Program
12.1.1 Required Floor Space and Room List
12.1.2 Process and Logistics Elements
12.1.3 Supply and Removal
12.1.4 Special Requirements
12.2 Building Typology
12.2.1 Sectional Profile
12.2.2 Outline Figure
12.2.3 Linking Principle
12.3 Property Protection
12.3.1 Burglary, Theft
12.3.2 Fire and Explosion Prevention
12.4 General Development (Master Plan)
12.4.1 Procedure
12.4.2 Zoning and Organizational Grid
12.4.3 Infrastructure, Supply and Removal Systems
12.4.4 Buildings and Open Spaces
12.5 Summary
Bibliography
13 Site Planning from Space View
13.1 Site Development
13.2 Utilities Supply and Disposal
13.3 Plot
13.3.1 Geometric Properties
13.3.2 Soil Characteristics
13.3.3 Obstacles and Edifices
13.4 Laws and Regulations
13.5 Site Evaluation
13.6 Environmental Aspects
13.7 Summary
Bibliography
14 Strategic Location Planning
14.1 Introduction
14.2 Location Planning Triggers
14.3 Suitability of the Current Structure
14.4 Location Factors
14.5 Procedure for Selecting a Location
14.6 Establishing Production Stages
14.7 Summary
Bibliography
15 The Synergetic Factory Planning Process
15.1 Planning Approach
15.2 Process Model
15.3 Goal Setting
15.3.1 Main Steps
15.3.2 Site Logistic Profile
15.3.3 Environment Analysis
15.3.4 Factors for Success
15.3.5 Change Drivers
15.3.6 Creating Scenarios
15.3.7 Finding a Vision
15.3.8 GENEering
15.3.9 Fields of Action
15.4 Base Analysis
15.4.1 Object Data
15.4.2 Process Analysis
15.5 Concept Planning
15.5.1 Structural Design
15.5.2 Dimensioning of the Structure
15.5.3 Rough Layout Planning
15.5.3.1 Types of Layouts
15.5.3.2 Ideal and Scaled Functional Scheme
15.5.3.3 Ideal 2D and 3D Rough Layout
15.5.3.4 Real Rough Layout
15.5.3.5 Evaluating Variants
15.6 Detailed Planning
15.6.1 Transportation Route System
15.6.2 Fine Layout
15.7 Energy Efficiency
15.7.1 Overview
15.7.2 Certification Systems
15.7.3 Case Studies
15.8 Preparations for Realization
15.9 Supervising the Realization
15.10 Managing the Ramp-up
15.11 Summary
Bibliography
16 Project Management
16.1 Tasks of Project Management
16.1.1 Stumbling Blocks
16.1.2 Task Overview
16.2 Project Organization
16.2.1 Team Building
16.2.2 Example of a Project Organization
16.2.3 Rules for Project Team
16.3 Project Plan Development
16.4 Project Capacity Planning
16.5 Contract Drafting
16.5.1 General
16.5.2 Award Variants
16.5.3 Advantages and Disadvantages of Award Variants
16.5.4 Liability Issues
16.6 Project Manual
16.7 Costing and Control
16.7.1 Conditions for Determining Costs
16.7.2 Costs in Building Construction
16.7.3 Usage Costs in Building Construction (According to German DIN 18960)
16.7.4 Cost Management
16.8 Digital Factory
16.8.1 Concept
16.8.2 Digital Tools
16.8.3 Simulation Example
16.9 Building Information Modeling
16.9.1 Introduction
16.9.2 Evaluation of the Building Information Model
16.9.3 Conclusion
16.10 Summary
Bibliography
17 Facilities Management
17.1 History and Definition
17.2 Tasks and Delimitation
17.3 Facilities Management in the Life Cycle of an Object
17.3.1 Development Phase
17.3.2 Implementation Phase
17.3.3 Operating Phase
17.3.4 Conversion Phase
17.3.5 Decommissioning Phase
17.4 Facility Management Systems
17.4.1 Functions
17.4.2 Structure of Data Models
17.4.2.1 Data Structuring
17.4.2.2 Layer Classification
17.4.2.3 3D-Building Model
17.4.2.4 Space Book
17.4.2.5 Documentation
17.4.3 Virtual Project Space
17.4.4 Navigation
17.4.5 Selection of a CAFM System
17.4.5.1 CAFM Consulting
17.5 Applications of Facility Management
17.5.1 Minimizing Maintenance Costs
17.5.2 Prevention of Allocation Conflicts
17.5.3 Spatial Planning
17.5.4 Lock Management and Key Management
17.5.5 Costs and Building State Control
17.5.6 Reporting
17.5.7 Fire Protection
17.6 Modeling of FM Processes
17.7 Case Studies
17.7.1 Phoenix AG Hamburg
17.7.2 Londa Rothenkirchen
17.8 Summary
Bibliography
Index