Handbook Factory Planning and Design

Structure of the Book

Hans-Peter Wiendahl •

Jürgen Reichardt • Peter Nyhuis

Handbook FactoryPlanning and Design

123

Hans-Peter WiendahlGarbsenGermany

Jürgen ReichardtFachbereich Baukonstruktion und

IndustriebauFachhochschule MünsterMünsterGermany

Peter NyhuisIFA Institut für Fabrikanlagen und

LogistikLeibniz Universität HannoverGarbsenGermany

ISBN 978-3-662-46390-1 ISBN 978-3-662-46391-8 (eBook)DOI 10.1007/978-3-662-46391-8

Library of Congress Control Number: 2015933365

Springer Heidelberg New York Dordrecht London© Springer-Verlag Berlin Heidelberg 2015This work is subject to copyright. All rights are reserved by the Publisher, whether the whole orpart of the material is concerned, specifically the rights of translation, reprinting, reuse ofillustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way,and transmission or information storage and retrieval, electronic adaptation, computer software,or by similar or dissimilar methodology now known or hereafter developed.The use of general descriptive names, registered names, trademarks, service marks, etc. in thispublication does not imply, even in the absence of a specific statement, that such names areexempt from the relevant protective laws and regulations and therefore free for general use.The publisher, the authors and the editors are safe to assume that the advice and information inthis book are believed to be true and accurate at the date of publication. Neither the publishernor the authors or the editors give a warranty, express or implied, with respect to the materialcontained herein or for any errors or omissions that may have been made.

Printed on acid-free paper

Springer-Verlag GmbH Berlin Heidelberg is part of Springer Science+Business Media(www.springer.com)

Translated by Rett Rossi

Additional material to this book can be downloaded from http://extras.springer.com.

Preface

The 1990s saw the rapid development of both the Internet and businesslogistics. Less than two decades later, the globalized economy was a reality.Nowadays, sustainability and resource efficiency are guiding principles to runa factory. The digital communication of orders, processes, and resources isthe next foreseeable development step in manufacturing.

Enterprises now frequently distribute their productions over several sitesin a number of countries, and their productions are usually subject to strongfluctuations. Individual sites thus have to be highly reactive and changeable.This in turn necessitates a paradigm change; generally speaking, we need toinvert the way we have traditionally considered a factory. Whereas previ-ously, the primary task of a parent company was seen as developing aproduct, producing it and processing orders, while procuring and distributingfinished goods to customers were secondary, today’s priority is reliablysupplying globally distributed markets from the most advantageous sites.Instead of central factories with a broad manufacturing depth, transformableor even temporary production sites located near the individual markets arenow essential.

With this in mind, we realized that a critical look at factory planning upuntil now had to be undertaken. In gathering information from numerousresearch projects and industrial-based projects conducted in various bran-ches, it became clear that in addition to the customary primary goal of beingas efficient as possible, additional demands have arisen:

• Depending on the impulse for change, a factory needs to be able to adjustitself within a suitable time period with regard to both production tech-nology and spatial demands on each of the impacted factory levels.

• Manufacturing and assembly systems need to take into consideration localperspectives concerning know-how, wage costs, and required value-adding(i.e., local content).

• Production facilities and buildings need to be designed so that they con-serve resources and are energy efficient.

• The external appearance of the factory needs to represent the corporateidentity of the enterprise, while the internal appearance needs to meet theclaim of the product.

• The spatial design of production sites needs to provide comfortableworkplaces, thereby expressing the company’s high regard for itsemployees.

v

In consideration of all this and over a number of years, we have developedthe tri-fold structure of this book. It is based on the second edition of theGerman “Handbuch Fabrikplanung” (Handbook Factory Planning),published in 2014 by Hanser Verlag Munich.

The first part of the book consists offive chapters and begins by developinga deeper understanding of the drivers behind factory changes and the resultingplanning basis including future demands. Following that, we review existingproduction concepts and conclude by deriving various characteristics of whatwe refer to as a ‘site’s changeability’.

In the second part of the book, we describe the planning and designprocess of a production site from the level of individual workstations to thelevel of various sections, up to the levels of the building and location itself.Depending on the level, we discuss strategic and functional planning aspectsas well as aspects pertaining to the actual organization of work—all with aspecial emphasis on changeability. Describing the spatial specifications ofthese levels plays a central role in directing the factory planner’s view to thenotion that form not only follows function, but also follows the performanceof the buildings and the building services they are equipped with.

With three chapters in the third part of the book, we focus on the sys-tematic factory planning process with respect to these new requirements. Thecenter of our discussion is the synergetic factory planning model. In sevenstages, it describes the creative interplay between production planning andspatial planning based on a continuous 3-D-modeling starting with the goal-setting right up to the ramp-up. The second chapter takes a look at projectmanagement, including the aspects of forming a project team, the responsi-bilities or team tasks, as well as a brief overview of digital tools for planninga factory. In view of the frequent changes of use, it becomes all the moreimportant to efficiently use real estate properties; the last chapter of the bookis therefore dedicated to facility management.

Our goal with this handbook is first and foremost to provide a compre-hensive, methodical, and practical support for the management of productionenterprises as well as for planners and designers of production sites. Thesame applies to architects and construction planners who design and realizeindustrial buildings. Moreover, this handbook is also intended for thosestudying production technology and industrial logistics from the perspectivesof both engineering and management, and for architecture and buildingconstruction students.

Before delving into our subject matter, we would like to thank first of allMrs. Rett Rossi, our most valued translator, who went deep into the complexsubject and delivered a perfect performance. Next to thank is Jens Lübke-mann from the IFA Institute of Production Systems and Logistics LeibnizUniversity, Hannover, for coordinating the work between the authors, ourreviewers, and Mrs. Rossi as well as the preparation of the correct format oftext and figures. Mr. Gerhard Hoffmann, CEO of IFES GmbH in Cologne,has contributed Sect. 11.3 and Detlef Gerst Chap. 7; to both, we have toexpress our sincere thanks. In addition, we are much indebted to IndranilBhattacharya, from the architectural firm Reichardt–Maas and Associates(Essen/Bangalore), for energetically supporting Chaps. 11–14 on spatial

vi Preface

planning especially with regard to adapting it to international aspects as wellas adding British building norms and quoting of English standard literaturesources. Many thanks go further to our colleagues Prof. Hoda and WaguihElMaraghy, University of Windsor Canada, and Prof. Neil Duffie, MadisonWisconsin University, for carefully reviewing several chapters. Last but notleast we would like to thank the members of the Scientific Publishing Ser-vices in Chennai, India for the excellent preparation of the final book lay out.This concerns mainly Mr. Udhaya Kumar P. and Ms. Shilpa Soundararajan.

Garbsen, March 2015 Hans-Peter WiendahlEssen Jürgen ReichardtGarbsen Peter Nyhuis

Preface vii

Contents

1 Factory Change Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1.1 Stagnant Factories . . . . . . . . . . . . . . . . . . . . 11.1.2 Previous Methods of Corporate

Management . . . . . . . . . . . . . . . . . . . . . . . . 31.1.3 Competitive Factors of Superior

Enterprises . . . . . . . . . . . . . . . . . . . . . . . . . 91.1.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Planning Basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.1 Production Strategies . . . . . . . . . . . . . . . . . . . . . . . . 132.2 Factory Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . 152.3 Market Offer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.4 Business Processes. . . . . . . . . . . . . . . . . . . . . . . . . . 202.5 Aspects of Factory Design . . . . . . . . . . . . . . . . . . . . 212.6 Manufacturing Location and Factory . . . . . . . . . . . . . 222.7 Morphology of Factory Types . . . . . . . . . . . . . . . . . . 232.8 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3 Production Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 293.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293.2 Responsiveness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293.3 Quantity and Variant Flexibility. . . . . . . . . . . . . . . . . 313.4 Focusing on Limits . . . . . . . . . . . . . . . . . . . . . . . . . 353.5 Self-organization and Participation . . . . . . . . . . . . . . . 403.6 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423.7 Networking and Cooperation. . . . . . . . . . . . . . . . . . . 433.8 Demographic Development . . . . . . . . . . . . . . . . . . . . 473.9 Corporate Culture . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.9.1 Organizational View . . . . . . . . . . . . . . . . . . 483.9.2 Architectural View. . . . . . . . . . . . . . . . . . . . 50

3.10 Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523.10.1 The Term and Concept. . . . . . . . . . . . . . . . . 523.10.2 Consequences for Factory Planning . . . . . . . . 563.10.3 Recycling Economy . . . . . . . . . . . . . . . . . . . 58

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3.11 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4 Known Production Concepts . . . . . . . . . . . . . . . . . . . . . . . 634.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634.2 F.W. Taylor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634.3 Group Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644.4 Manufacturing Cells. . . . . . . . . . . . . . . . . . . . . . . . . 674.5 Flexible Manufacturing Systems . . . . . . . . . . . . . . . . 694.6 Manufacturing Segments . . . . . . . . . . . . . . . . . . . . . 694.7 Lean Production and the Toyota Production

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714.8 Just-in-Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754.9 Fractal Enterprises . . . . . . . . . . . . . . . . . . . . . . . . . . 784.10 Agility Oriented Competition . . . . . . . . . . . . . . . . . . 784.11 Mass Customization . . . . . . . . . . . . . . . . . . . . . . . . . 804.12 Production Stages Concept . . . . . . . . . . . . . . . . . . . . 814.13 Research Approaches . . . . . . . . . . . . . . . . . . . . . . . . 844.14 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5 Systematics of Changeability . . . . . . . . . . . . . . . . . . . . . . . 915.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 915.2 Flexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 915.3 Reconfigurability . . . . . . . . . . . . . . . . . . . . . . . . . . . 965.4 Changeability and Change Enablers . . . . . . . . . . . . . . 965.5 Aspects of Designing Changeability . . . . . . . . . . . . . . 1025.6 Morphology of Changeability . . . . . . . . . . . . . . . . . . 1035.7 Classes of Changeability for Production

Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1065.8 Evaluating Changeability . . . . . . . . . . . . . . . . . . . . . 1095.9 Vision of the Changeable Factory . . . . . . . . . . . . . . . 1145.10 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

6 Functional Design of Workplaces . . . . . . . . . . . . . . . . . . . . 1196.1 Design Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1196.2 Production Technology. . . . . . . . . . . . . . . . . . . . . . . 122

6.2.1 Manufacturing Processes. . . . . . . . . . . . . . . . 1226.2.2 Assembly Methods . . . . . . . . . . . . . . . . . . . 1266.2.3 Logistic Processes . . . . . . . . . . . . . . . . . . . . 132

6.3 Facilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1406.3.1 Manufacturing Facilities . . . . . . . . . . . . . . . . 1416.3.2 Assembly Systems . . . . . . . . . . . . . . . . . . . . 1496.3.3 Logistical Resources . . . . . . . . . . . . . . . . . . 158

6.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

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7 Designing Workplaces from a Work OrganizationalPerspective by Detlef Gerst . . . . . . . . . . . . . . . . . . . . . . . . 1697.1 Human Resources as a Concept. . . . . . . . . . . . . . . . . 1697.2 Human Resources and Production Performance . . . . . . 1707.3 Competency and Human Resources Development . . . . 170

7.3.1 Professional Competence . . . . . . . . . . . . . . . 1717.3.2 Strategies for Developing Competence . . . . . . 1727.3.3 Human Resources Development. . . . . . . . . . . 174

7.4 Work Structuring . . . . . . . . . . . . . . . . . . . . . . . . . . . 1757.5 Motivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1777.6 Designing Remuneration Systems . . . . . . . . . . . . . . . 1797.7 Planning Working Times . . . . . . . . . . . . . . . . . . . . . 1847.8 Influence of Demographic Change . . . . . . . . . . . . . . . 1897.9 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

8 Spatial Workplace Design . . . . . . . . . . . . . . . . . . . . . . . . . 1978.1 Ergonomics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1978.2 Room Interiors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2008.3 Color Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

8.3.1 Psychological Impact of Color. . . . . . . . . . . . 2028.3.2 Safety Colors and Identification

of Media Lines . . . . . . . . . . . . . . . . . . . . . . 2038.3.3 Holistic Color Schemes . . . . . . . . . . . . . . . . 203

8.4 Occupational Health and Safety Standards . . . . . . . . . 2048.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 2048.4.2 Workplace Regulations . . . . . . . . . . . . . . . . . 2048.4.3 Participation . . . . . . . . . . . . . . . . . . . . . . . . 2068.4.4 Tread Certainty and Protection

Against Fall . . . . . . . . . . . . . . . . . . . . . . . . 2078.4.5 Protection from Hazardous Substances . . . . . . 2088.4.6 Noise Protection and Reduction . . . . . . . . . . . 2088.4.7 Protection from Thermal Radiation

and Vibrations. . . . . . . . . . . . . . . . . . . . . . . 2098.4.8 Electrical Safety and Protection

from Radiation . . . . . . . . . . . . . . . . . . . . . . 2128.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

9 Functional Design of Work Areas . . . . . . . . . . . . . . . . . . . 2159.1 Overview of Design Aspects . . . . . . . . . . . . . . . . . . . 2159.2 Customer Order Decoupling Point . . . . . . . . . . . . . . . 2169.3 Approaches to Handling Orders. . . . . . . . . . . . . . . . . 2179.4 Order Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2199.5 Process Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

9.5.1 Procurement Models . . . . . . . . . . . . . . . . . . 2209.5.2 Production Models . . . . . . . . . . . . . . . . . . . . 2229.5.3 Delivery Models . . . . . . . . . . . . . . . . . . . . . 222

9.6 Manufacturing and Assembly Principles . . . . . . . . . . . 223

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9.7 Production Segments . . . . . . . . . . . . . . . . . . . . . . . . 2269.8 Production Planning and Control . . . . . . . . . . . . . . . . 2279.9 Selecting and Configuring a Production

Control Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2309.10 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

10 Spatial Workspace Design . . . . . . . . . . . . . . . . . . . . . . . . . 23910.1 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

10.1.1 Corridors, Stairwells, Intermediary Spaces. . . . 24010.1.2 Arranging and Linking Workspaces . . . . . . . . 24210.1.3 Location, Shape and Furnishings

of Common Areas . . . . . . . . . . . . . . . . . . . . 24410.2 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

10.2.1 Daylight . . . . . . . . . . . . . . . . . . . . . . . . . . . 24510.2.2 Natural Lighting . . . . . . . . . . . . . . . . . . . . . 24610.2.3 Artificial Lighting . . . . . . . . . . . . . . . . . . . . 24810.2.4 Redirecting Light . . . . . . . . . . . . . . . . . . . . . 251

10.3 Comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25210.4 Relaxation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

10.4.1 Break-Out Areas and Social Rooms . . . . . . . . 25510.4.2 Canteen, Cafeteria, Coffee Corners. . . . . . . . . 25510.4.3 Sport, Recreation and Spare Time . . . . . . . . . 255

10.5 Fire Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25610.5.1 Fire Protection Concept and Fire

Compartment . . . . . . . . . . . . . . . . . . . . . . . 25710.5.2 Clearances, Firewalls and Complex

Separation Walls . . . . . . . . . . . . . . . . . . . . . 25710.5.3 Fire Resistance Rating Classes. . . . . . . . . . . . 25910.5.4 Evacuation and Rescue Routes . . . . . . . . . . . 26010.5.5 Smoke and Heat Ducts, Fire Extinguishing

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 26110.6 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

11 Building Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26511.1 Load-Bearing Structure. . . . . . . . . . . . . . . . . . . . . . . 267

11.1.1 Project Requirements and LoadAssumption. . . . . . . . . . . . . . . . . . . . . . . . . 267

11.1.2 Building Structure Form as a StaticSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

11.1.3 Span Width. . . . . . . . . . . . . . . . . . . . . . . . . 27211.1.4 Selecting the Materials and Joining

Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . 27311.1.5 Profiling Support Columns, Beams

and Ceiling Slabs. . . . . . . . . . . . . . . . . . . . . 27611.2 Shells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

11.2.1 Protective Functions. . . . . . . . . . . . . . . . . . . 27811.2.2 Production and Logistics. . . . . . . . . . . . . . . . 279

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11.2.3 Lighting, Views, Communication. . . . . . . . . . 28011.2.4 Ecology and Energy Production. . . . . . . . . . . 281

11.3 Building Services . . . . . . . . . . . . . . . . . . . . . . . . . . 28211.3.1 Supply and Removal Systems . . . . . . . . . . . . 28311.3.2 Technical Centers . . . . . . . . . . . . . . . . . . . . 28411.3.3 Main Routings . . . . . . . . . . . . . . . . . . . . . . 28611.3.4 Line Nets . . . . . . . . . . . . . . . . . . . . . . . . . . 28711.3.5 Inlets and Outlets. . . . . . . . . . . . . . . . . . . . . 28711.3.6 Building Services. . . . . . . . . . . . . . . . . . . . . 288

11.4 Interior Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . 29811.4.1 Floors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29911.4.2 Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30111.4.3 Ceilings . . . . . . . . . . . . . . . . . . . . . . . . . . . 30211.4.4 Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30411.4.5 Stairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

11.5 Examples of Changeable Buildings . . . . . . . . . . . . . . 30511.6 Grace and Aesthetics . . . . . . . . . . . . . . . . . . . . . . . . 306

11.6.1 Structural Order. . . . . . . . . . . . . . . . . . . . . . 30711.6.2 Simplicity . . . . . . . . . . . . . . . . . . . . . . . . . . 30811.6.3 Balance Between Unity and Diversity . . . . . . 30811.6.4 Distinctiveness . . . . . . . . . . . . . . . . . . . . . . 30811.6.5 Emotional Quality, Atmosphere . . . . . . . . . . . 308

11.7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

12 Master Building Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31112.1 Request Program . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

12.1.1 Required Floor Space and Room List . . . . . . . 31112.1.2 Process and Logistics Elements . . . . . . . . . . . 31412.1.3 Supply and Removal . . . . . . . . . . . . . . . . . . 31512.1.4 Special Requirements . . . . . . . . . . . . . . . . . . 317

12.2 Building Typology. . . . . . . . . . . . . . . . . . . . . . . . . . 31712.2.1 Sectional Profile . . . . . . . . . . . . . . . . . . . . . 31812.2.2 Outline Figure . . . . . . . . . . . . . . . . . . . . . . . 32012.2.3 Linking Principle . . . . . . . . . . . . . . . . . . . . . 322

12.3 Property Protection . . . . . . . . . . . . . . . . . . . . . . . . . 32212.3.1 Burglary, Theft . . . . . . . . . . . . . . . . . . . . . . 32212.3.2 Fire and Explosion Prevention. . . . . . . . . . . . 324

12.4 General Development (Master Plan) . . . . . . . . . . . . . . 32412.4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 32412.4.2 Zoning and Organizational Grid. . . . . . . . . . . 32512.4.3 Infrastructure, Supply and Removal

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 32612.4.4 Buildings and Open Spaces. . . . . . . . . . . . . . 327

12.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

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13 Site Planning from Space View . . . . . . . . . . . . . . . . . . . . . 33113.1 Site Development . . . . . . . . . . . . . . . . . . . . . . . . . . 33113.2 Utilities Supply and Disposal . . . . . . . . . . . . . . . . . . 33213.3 Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

13.3.1 Geometric Properties . . . . . . . . . . . . . . . . . . 33313.3.2 Soil Characteristics . . . . . . . . . . . . . . . . . . . 33413.3.3 Obstacles and Edifices . . . . . . . . . . . . . . . . . 335

13.4 Laws and Regulations . . . . . . . . . . . . . . . . . . . . . . . 33513.5 Site Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33613.6 Environmental Aspects . . . . . . . . . . . . . . . . . . . . . . . 33813.7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

14 Strategic Location Planning . . . . . . . . . . . . . . . . . . . . . . . . 34114.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34114.2 Location Planning Triggers . . . . . . . . . . . . . . . . . . . . 34114.3 Suitability of the Current Structure. . . . . . . . . . . . . . . 34314.4 Location Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . 34514.5 Procedure for Selecting a Location. . . . . . . . . . . . . . . 35014.6 Establishing Production Stages . . . . . . . . . . . . . . . . . 35214.7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

15 The Synergetic Factory Planning Process . . . . . . . . . . . . . . 36115.1 Planning Approach . . . . . . . . . . . . . . . . . . . . . . . . . 36115.2 Process Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36515.3 Goal Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

15.3.1 Main Steps . . . . . . . . . . . . . . . . . . . . . . . . . 37315.3.2 Site Logistic Profile . . . . . . . . . . . . . . . . . . . 37415.3.3 Environment Analysis . . . . . . . . . . . . . . . . . 37615.3.4 Factors for Success . . . . . . . . . . . . . . . . . . . 37715.3.5 Change Drivers . . . . . . . . . . . . . . . . . . . . . . 37715.3.6 Creating Scenarios . . . . . . . . . . . . . . . . . . . . 37815.3.7 Finding a Vision . . . . . . . . . . . . . . . . . . . . . 38115.3.8 GENEering . . . . . . . . . . . . . . . . . . . . . . . . . 38115.3.9 Fields of Action . . . . . . . . . . . . . . . . . . . . . 383

15.4 Base Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38415.4.1 Object Data. . . . . . . . . . . . . . . . . . . . . . . . . 38615.4.2 Process Analysis . . . . . . . . . . . . . . . . . . . . . 389

15.5 Concept Planning . . . . . . . . . . . . . . . . . . . . . . . . . . 39415.5.1 Structural Design . . . . . . . . . . . . . . . . . . . . . 39515.5.2 Dimensioning of the Structure . . . . . . . . . . . . 39915.5.3 Rough Layout Planning . . . . . . . . . . . . . . . . 405

15.6 Detailed Planning . . . . . . . . . . . . . . . . . . . . . . . . . . 41515.6.1 Transportation Route System. . . . . . . . . . . . . 41515.6.2 Fine Layout . . . . . . . . . . . . . . . . . . . . . . . . 415

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15.7 Energy Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . 41915.7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 41915.7.2 Certification Systems . . . . . . . . . . . . . . . . . . 42315.7.3 Case Studies . . . . . . . . . . . . . . . . . . . . . . . . 424

15.8 Preparations for Realization . . . . . . . . . . . . . . . . . . . 43015.9 Supervising the Realization . . . . . . . . . . . . . . . . . . . . 43115.10 Managing the Ramp-up . . . . . . . . . . . . . . . . . . . . . . 43215.11 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

16 Project Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43516.1 Tasks of Project Management . . . . . . . . . . . . . . . . . . 435

16.1.1 Stumbling Blocks . . . . . . . . . . . . . . . . . . . . 43516.1.2 Task Overview . . . . . . . . . . . . . . . . . . . . . . 436

16.2 Project Organization. . . . . . . . . . . . . . . . . . . . . . . . . 43816.2.1 Team Building . . . . . . . . . . . . . . . . . . . . . . 43816.2.2 Example of a Project Organization . . . . . . . . . 43916.2.3 Rules for Project Team. . . . . . . . . . . . . . . . . 440

16.3 Project Plan Development. . . . . . . . . . . . . . . . . . . . . 44116.4 Project Capacity Planning . . . . . . . . . . . . . . . . . . . . . 44416.5 Contract Drafting. . . . . . . . . . . . . . . . . . . . . . . . . . . 444

16.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . 44416.5.2 Award Variants . . . . . . . . . . . . . . . . . . . . . . 44516.5.3 Advantages and Disadvantages

of Award Variants . . . . . . . . . . . . . . . . . . . . 44616.5.4 Liability Issues . . . . . . . . . . . . . . . . . . . . . . 446

16.6 Project Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44716.7 Costing and Control . . . . . . . . . . . . . . . . . . . . . . . . . 447

16.7.1 Conditions for Determining Costs . . . . . . . . . 44816.7.2 Costs in Building Construction . . . . . . . . . . . 44916.7.3 Usage Costs in Building Construction

(According to German DIN 18960) . . . . . . . . 45016.7.4 Cost Management . . . . . . . . . . . . . . . . . . . . 452

16.8 Digital Factory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45416.8.1 Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . 45416.8.2 Digital Tools . . . . . . . . . . . . . . . . . . . . . . . . 45816.8.3 Simulation Example . . . . . . . . . . . . . . . . . . . 460

16.9 Building Information Modeling . . . . . . . . . . . . . . . . . 46216.9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 46216.9.2 Evaluation of the Building Information

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46416.9.3 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . 470

16.10 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471

17 Facilities Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47317.1 History and Definition . . . . . . . . . . . . . . . . . . . . . . . 47317.2 Tasks and Delimitation. . . . . . . . . . . . . . . . . . . . . . . 474

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17.3 Facilities Management in the Life Cycleof an Object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47517.3.1 Development Phase . . . . . . . . . . . . . . . . . . . 47517.3.2 Implementation Phase. . . . . . . . . . . . . . . . . . 47617.3.3 Operating Phase . . . . . . . . . . . . . . . . . . . . . 47817.3.4 Conversion Phase . . . . . . . . . . . . . . . . . . . . 47817.3.5 Decommissioning Phase . . . . . . . . . . . . . . . . 479

17.4 Facility Management Systems . . . . . . . . . . . . . . . . . . 47917.4.1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 47917.4.2 Structure of Data Models . . . . . . . . . . . . . . . 48017.4.3 Virtual Project Space . . . . . . . . . . . . . . . . . . 48617.4.4 Navigation . . . . . . . . . . . . . . . . . . . . . . . . . 48617.4.5 Selection of a CAFM System . . . . . . . . . . . . 488

17.5 Applications of Facility Management . . . . . . . . . . . . . 48917.5.1 Minimizing Maintenance Costs . . . . . . . . . . . 48917.5.2 Prevention of Allocation Conflicts . . . . . . . . . 49017.5.3 Spatial Planning . . . . . . . . . . . . . . . . . . . . . 49017.5.4 Lock Management and Key Management . . . . 49117.5.5 Costs and Building State Control . . . . . . . . . . 49117.5.6 Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . 49117.5.7 Fire Protection. . . . . . . . . . . . . . . . . . . . . . . 491

17.6 Modeling of FM Processes . . . . . . . . . . . . . . . . . . . . 49217.7 Case Studies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493

17.7.1 Phoenix AG Hamburg . . . . . . . . . . . . . . . . . 49317.7.2 Londa Rothenkirchen . . . . . . . . . . . . . . . . . . 493

17.8 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496

Erratum to: Handbook Factory Planning and Design . . . . . . . . E1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497

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About the Authors

Hans-Peter Wiendahl born in 1938, studiedMechanical Engineering at the RWTH Aachenand at MIT USA and worked after that as juniorresearcher for 4 years at the WZL Laboratory forMachine Tools and Production Engineering inUniversity of Aachen. There, he received aDoctorate in Engineering in 1970, and in 1972 hegraduated as lecturer (Dr.-Ing habil.). From 1972to 1979, he moved to a large machine buildingcompany working in different management posi-tions. From 1979 until 2003, Wiendahl wasappointed Full-time Professor and Director of theInstitute of Production Systems and Logistics at

the Leibniz Universität Hannover (www.ifa.uni-hannover.de). Prof. Wiendahlis full member of the German Academic Society for Production Engineering(WGP) and Emeritus Member of the International Academy for ProductionEngineering CIRP. He has authored more than 10 books and over 300 articlesin the field of Factory Planning, Assembly, and production logistics. Hereceived three doctorates of honor from the Universities of Magdeburg, ETHZurich, and Dortmund and the SME Golden Medal.

Jürgen Reichardt born in 1956, studied Archi-tecture at the University of Karlsruhe and theTechnische Universität Braunschweig. From1988 to 1995, he worked as project manager fordesign and implementation of complex industrialbuildings at Agiplan AG in Mülheim/Ruhr. In1992, he founded his office Reichardt Architectswith a focus on planning of industrial plants andlogistics centers at home and abroad. Since 1996,he is Professor in Industrial Construction at theMuenster school of architecture (https://www.fh-

muenster.de). In 2006, he founded the office Bhattacharya ReichardtArchitects & Engineers in Bangalore (BRAE), India, and operates since 2008its German office as RMA Reichardt–Maas–Associated Architects GmbH &Co. KG in Essen.

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Peter Nyhuis born in 1957, studied Mechan-ical Engineering at the Leibniz UniversitätHannover. He received his Ph.D. in 1991 afterhis time as junior researcher at the Institute forProduction Systems and Logistics. In 1999, hewas graduated as lecturer (Dr.-Ing. habil.).From 1999 to 2003, Professor Nyhuis workedat Siemens AG in SPLS Supply Chain Con-sulting, an in-house consulting entity. In 2003,he was appointed as Full-time Professor andManaging Director of the Institute for Pro-duction Systems and Logistics at the LeibnizUniversität Hannover for the topics factoryplanning, production logistics, assembly plan-

ning, and Industrial Engineering. Since 2008, he is also Managing Director ofthe Institute of Integrated Production Hannover (IPH). Prof. Nyhuis is fullmember of the German Academic Society for Production Engineering(WGP), Associate Member of the International Academy for ProductionEngineering (CIRP), and member of the International Federation for Infor-mation Processing (IFIP) (Working Group 5.7: Production Control). He isauthor of several books and book chapters on production planning andcontrol, logistic curves, factory planning, and procurement logistics.

xviii About the Authors