facilities planning - baixardoc
TRANSCRIPT
INSTRUCTOR’S MANUAL TO ACCOMPANY
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
PREFACE
The Instructor's Manual provides answers to the questions and solutions to the problems at the
end of the chapters in the Fourth Edition of Facilities Planning. When a question or problem is
open-ended, either no answer is provided or guidance is provided relative to the response
intended.
Due to human error, it is possible that mistakes exist in the responses provided. Several changes
were made to end-of-chapter questions and problems during the production process.
Consequently, it is possible that responses are provided in the Instructor's Manual in anticipation
of changes to the manuscript that did not occur. If you encounter an error in the Instructor's
Manual, the authors request that you bring it to the attention of Dr. James A. Tompkins, who was
coordinating author for this edition of Facilities Planning. Correspondence should be sent to
Dr. James A. Tompkins, President and CEO, Tompkins Associates, Inc., 8970 Southall Road,
Raleigh, NC 27616. If more convenient, you can communicate errors via email using the
address: [email protected].
This electronic version of the Instructor's Manual is available to faculty who adopt Facilities
Planning. To prevent widespread dissemination of answers and solutions to end-of-chapter
questions and problems, the authors and publisher require that you use password-protected
access to course websites containing solutions to problems for students. Further, passwords must
be changed after each offering of the course. Many instructors do not want students to have
access to the Instructor's Manual. Hence, it is important for access to be limited.
To prepare the Third Edition of Facilities Planning, coordinating authors were assigned for each
chapter. Dr. Tompkins had coordinating responsibility for Chapters 1, 4, 5, and 9; Dr. White had
coordinating responsibility for Chapters 11, and 12; Dr. Bozer had coordinating responsibility for
Chapters 6 and 7; Dr. Tanchoco had coordinating responsibility for Chapters 2, 3, and 8; and
Drs. Bozer, White, and Tanchoco shared coordinating responsibility for Chapter 10. Hence,
depending on the nature of questions you have regarding material in a chapter, you might wish to
contact directly the coordinating author. Contact information for each author is provided
following the preface.
To assist you in finding material for a particular chapter, the page numbering in the Instructor’s Manual incorporates the chapter number. In addition, the manual contains two-levels of
bookmarks. The first level corresponds to major divisions of the manual, e.g. parts and chapters.
The second level corresponds to the section of each chapter from which the questions originate,
which is consistent with the problem groupings at the end of each chapter of the textbook. In
this way, we believe you will be able to turn more quickly to the response of interest to you.
We are pleased to acknowledge the assistance of a number of individuals in developing the
material for the Instructor’s Manual. The solutions manual for the fourth edition was compiled
by Patrick Brunese (Purdue University). For the previous editions, we express our appreciation
to David Ciemnoczolowski (University of Michigan), Ronald Gallagher (Tompkins Associates),
E. Harjanto (Purdue University), Mark Rukamathu (University of Arkansas), and S. Sugiarta
(Purdue University).
Thank you for adopting Facilities Planning. We trust it measures up to your expectations and
you view it as an improvement over the previous editions. We have endeavored to respond to all
feedback we received from instructors who used the previous editions of the text. And, as in the
past, we welcome your suggestions for ways to improve the book.
James A. Tompkins
John A. White
Yavuz A. Bozer
J. M. A. Tanchoco
Author’s Addresses
James A. Tompkins
President and CEO
Tompkins Associates, Inc.
8970 Southall Road
Raleigh, NC 27616
919-876-3667 (B)
919-872-9666 (F)
John A. White
Chancellor Emeritus and Distinguished
Professor of Industrial Engineering
University of Arkansas
308 Engineering Hall
Fayetteville, AR 72701
479-575-2773 (B)
479-575-8431 (F)
Yavuz A. Bozer
Professor
Department of Industrial and
Operations Engineering
University of Michigan
Ann Arbor, MI 48109
734-936-2177 (B)
734-764-3451 (F)
J. M. A. Tanchoco
Professor
School of Industrial Engineering
Purdue University
Grissom Hall
West Lafayette, IN 47907
317-494-4379 (B)
317-494-5448 (F)
Table of Contents
Chapter Title
No. of
Pages
Part One Defining Requirements
1 Introduction 15
2 Product, Process, and Schedule Design 33
3 Flow Systems, Activity Relationships, and Space Requirements 12
4 Personnel Requirements 7
Part Two Developing Alternatives : Concepts and Techniques
5 Material Handling 6
6 Layout Planning Models and Design Algorithms 31
Part Three Facility Design for Various Facility Functions
7 Warehouse Operations 11
8 Manufacturing Systems 6
9 Facilities Systems 8
Part Four Developing Alternatives: Quantitative Approaches
10 Quantitative Facilities Planning Models 112
Part Five Evaluating, Selecting, Preparing, Presenting, Implementing, and
Maintaining
11 Evaluating and Selecting the Facilities Plan 10
12 Preparing, Presenting, Implementing, and Maintaining the Facilities Plan 4
Chapter 1
Introduction
Answers to Problems at the End of Chapter 1 1-1
SECTION 1.1
1.1a To plan for a football game, a visiting head football coach must:
Make sure that his players and coaches understand the game plan
Prepare his players physically and mentally for the game
Study opposing team game films
Understand strengths and weaknesses of the opponent
Maintain the discipline of his players
To operate the team during a football game, a visiting head coach must:
Continuously update his game plan based upon what the opposing team does
Communicate these updates with his coaches and players
Keep players physically ready to play
Replace injured players with other quality players if at all possible
Call the best plays that will score the most points and make victory most likely
1.1b To plan for a football game, the home team quarterback must:
Practice drills and fundamentals
Understand role in game plan
Become familiar with pass receivers' skills and abilities
Assume leadership role of team
The operating activities that a home team quarterback must do are:
Operate coaches’ game plan on the field
Lead team against opposition
Use skills learned in practice
Minimize mistakes
Relay plans from sidelines to all players in the huddle
Win the game
1.1c To plan for a football game, the manager of refreshment vending must:
Make sure all food, beverages, condiments, and paper supplies are ordered and
stocked
Hire employees to work the vending locations
Pay suppliers
Understand what refreshments field personnel will need during the game
The operating activities that a manager of refreshment vending must do are:
Serve customers as efficiently and professionally as possible
Restock vending locations whenever necessary
Keep fans updated on game activities with televisions at vending locations
Solve customer problems
1.1d To plan for a football game, the ground crew manager must ensure that:
Answers to Problems at the End of Chapter 1 1-2
Lines are painted on the field
Grass is mowed
Damaged turf is replaced
Necessary equipment for the teams is in its proper place
Locker rooms are prepared for the teams
The operating activities that a ground crew manager must do are:
Replace damaged turf, if possible, during the game if weather is bad
Be ready for any grounds problems that may arise during the game
1.1e To plan for a football game, the stadium maintenance manager must:
Examine plumbing fixtures to make sure they are operational
Clean the stadium and pick up trash from the previous event
Repair any seats or bleachers that are damaged
Clean bathrooms
Repair and replace any necessary audio or video equipment for the stadium
The operating activities that a stadium maintenance manager must do are:
Respond to any equipment breakdown
Respond to any plumbing breakdown
Respond to any power outage
1.2 Ten components of a football facility are:
The stadium structure
Parking lots around the stadium
Vendor selling areas
Maintenance components
Grounds-keeping equipment and personnel
Security
Customers
Athletic team personnel
Locker rooms
Vending equipment and supplies
1.3a Activities that would be involved in planning the location of an athletic stadium are:
Marketing analysis: Is there a fan base to support the teams or events that will
occupy the facility?
Determining a suitable plot of land for the facility and its associated parking lots in
terms of size and levelness
Determine by what routes suppliers will supply the facility
Determine if there are other facilities that will interact with the stadium and how the
location of the facility will affect those interactions
Determine if existing structures will need to be demolished to accommodate the
new stadium and how those people or businesses will be compensated
Determine the stability of the land that will be used to hold this structure
Answers to Problems at the End of Chapter 1 1-3
1.3b Activities that would be involved in planning the design of an athletic stadium are to
determine the facility layout and systems and the material handling systems that are
necessary to operate the facility. Items that need to be determined within the facility
layout are as follows:
Number of people it will need to hold
Equipment is necessary to run this facility.
How the facility can host multiple types of sports—the design must accommodate
all of them
Whether the stadium be an outdoor stadium or a domed stadium
Artificial or natural turf
Materials of the track surface be
How and where upper-deck access will be
Vending locations in the facility
Where administrative offices of the facility will be
How many restrooms there will be and their locations
Where the locker rooms will be
Facilities systems that need to be examined are:
Structural and enclosure elements.
Power and natural gas requirements
Lighting requirements
Heating, ventilation and air conditioning requirements
Water and sewage needs
Handling systems that need to be examined are:
Material handling system
Personnel required to operate the stadium
Information systems required to operate the stadium
Equipment needed to support the stadium
1.3c Activities that would be involved in facilities planning for an athletic stadium are
determining the facility location and design, explained in greater detail in 1.3a and 1.3b,
plus the ongoing maintenance and improvement of the facility.
1.4 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
Answers to Problems at the End of Chapter 1 1-4
well as where the communication points within the network will be located. 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.
SECTION 1.3
1.5 Use the following criteria for determining the optimal facilities plan:
Does the facility provide for the company’s future storage requirements?
Is there cost justification for the facility?
Is the facility centrally located for suppliers or customers if it is a manufacturing
facility; for manufacturing centers if it is a shipping warehouse; for fans if it is an
athletic facility, etc.?
Does it minimize receiving and putaway times while providing enough spaces for
those functions?
Does the product from the manufacturing operations flow smoothly through the
facility?
Are there enough dock doors for shipping and receiving functions?
Is the material handling equipment proper for the product that is being moved? Is
there enough space for the equipment to maneuver around the facility?
Is the lease cost, property cost, or building cost cheaper than other alternatives?
Can the manufacturing or warehouse facility accommodate sales forecasts?
Does the plan minimize the cost of operation in terms of labor and equipment?
Will scrap be minimized with this plan?
Can the facility be expanded easily to accommodate growth?
Is space being utilized to the highest extent?
1.6 This answer will vary from campus to campus, but some things of which the student
should be aware are:
Traffic patterns on campus
Whether administration offices are easily accessible
Handicapped accessibility to all buildings
Whether areas mix high vehicle and pedestrian traffic
What it would take to remove dilapidated buildings