Handbook Factory Planning And Design

Description

This handbook introduces a methodical approach and pragmatic concept for the planning and design of changeable factories, proven in many industrial projects. In the first part, change drivers of manufacturing enterprises and the resulting new challenges are considered. The second part concerns the design of the production facilities on the different factory levels under functional, organizational, architectural and strategic aspects considering environmental, health and safety aspects. The third part is dedicated to the planning process that is based on a synergetic interaction of process and space. The accompanying project management of the planning and construction phase and the facility management for the effective utilization of the built premises close the book. See Also: • https://extras.springer.com/?query=978-3-662-46391-8 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