Description of the Appendices to be printed after Chapter 17
Appendix A
Determining the Changeability Potential of Factory Objects
Appendix A1 Definition of Factory Objects
In this appendix, the factory objects of the 1st and 2nd order – sorted according to
the factory levels from site to workplace and the factory fields (technology, organization and space) – are listed according to the following overview. Section 5.7 ‘Evaluating Changeability’ discusses the application of this analysis.
factory fields
technology
organization
space
factory levels
site
factory
section
sub-section
workstation
T!0 building service
centers
O10 hierarchical
structure
S10 property
S20 site development
plan
S30 outdoor areas
T20 building service
distribution
facilities
T30 information
technology
O20 production concept S40 layout
O30 logistics concept
S50 building form
O40 factory structure
S60 building structure
S70 shell
S80 appearance
T40 storage facilities
T50 conveying
facilities
O50 work organization
S90 building interiors
T60 production
technology
T70 production
facilities
T80 other facilities
O60 quality
management
concept
S100 workplace design
Overview of Factory Objects (see Chapter. 5, Fig 5.18)
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The following example shows the breakdown of the factory object ‘production facilities’.
Factory Object
1st Order
Factory Objects
2nd Order
T70
Production Facilities
T70.1
T70.2
T70.3
T70.4
T70.5
T70.6
T70.7
Foundation
Frame
Drives
Kinematic System
Control, Recording and Diagnosis Systems
Peripheral and Auxiliary Systems
Tools
Example of the Breakdown and Definition of the Factory Object ‘Production
Facilities’
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Appendix A2 Change Drivers
In this section, we define the factory change drivers and identify which driver class
(volume, variants, target or element) they belong to.
Examples of Features of Changeability Potential of Production Facilities
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Appendix B
Space Book
The spreadsheets describe the geometry (net area, clearance height) and room requirements (floors, walls, ceiling, facilities) as well as the resulting building service
requirements and requirements related to the processes that take place in the room,
for each room and each level of the building.
The use of space books is discussed in Chapter 16 “Project Management” in Section
16.1.2 “Overview of Responsibilities”.
a) entries per floor
b) summary of each floor
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Appendix C
The following appendix contains documents and tables to be used in conducting a
factory planning project.
Appendix C1 Goal Setting
This file contains all of the templates necessary for conducting a goal setting workshop aimed at evaluating an enterprises manufacturing location according to the following order of events.
09:00 Welcoming and target of the workshop
(10 min)
Expectations of the participants
(10 min)
09:30 Impulse paper (Overview Modern Factories)
(45 min)
10:30 Coffee break
(15 min)
10:45 Corporate and environmental analysis
(60 min)
11:45 Vision Targets and Strategies
(60 min)
12:45 Lunch
(45 min)
13:30 Aptitude test of the location
15:30 Coffee break
(120 min)
(30 min)
16:00 Definition of the guidelines and action fields Moderation (60 min)
17:30 Feed bake the participants
(30 min)
18:00 End of workshop
The outcomes inserted as an example are from an actual workshop and illustrate
typical results.
A more precise overview of a workshop is described based on a further example in
Section 15.3 “Goal Setting”.
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Appendix C2 Required Data Checklist
Below is an example of a data checklist, which details the data that may be necessary for analyzing a factory. Its application is described in Section 15.4 “Base Analysis”.
Required Data Checklist (Excerpt)
Appendix C3 Benefit Value Analysis
This Excel application facilitates the analysis of optional concepts based on a
weighted list of criteria. Criteria are weighted by comparing them in pairs. The end
result of a benefit value analysis reflects the degree to which the alternative fulfills
requirements.
The application of the benefit value analysis is discussed in Section 15.5.3.5 “Evaluation”.
Example of a Benefit Value Analysis for four Alternative Concepts
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Appendix D
Appendix D 1
Video Animation of a Feasibility Study for a Cosmetic Manufacturer
(Londa in Rothenkirchen, Germany)
Sample Scene
The quality of the feasibility study lies in the synergetic synopsis of the objectives (in
relation to the location, processes and organization, buildings and building services)
that have been elaborated in a comprehensive spatial model. With relatively manageable amount of effort, the 3D data from the process and building planning can be
used to develop a video animation. Functional - organizational relationships between
the location and process planning, especially their interplay with the building (e.g.,
utility aspects such as communication or the use of natural day light) can be conveyed to all of the project team members, investors, authorities or also later users in
a visual way. Particularly when comparatively evaluating possible alternative plans,
the immediate persuasiveness of moving images can be a tremendous advantage.
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Process animations such as material flow simulations can be embedded in the storyboard which the project team develops and agrees upon before the animation is created.
The video animation supplied in Appendix D1 shows the integration of a new modularly designed manufacturing hall for a cosmetic product in a mature plant structure.
Particular aspects include
 the representation of the topographic embedding in the existing slight ground
slope,
 the rough 3D representation of the processing equipment,
 the structural relationship between the load-bearing framework and
 the modular building services
 as well as the demonstration of the spatial transparency, communication and
the views in the new plant.
The video animation was used to discuss the objectives of the plant expansion in particular with the future users.
Incorporating the video animation into the synergetic planning process is described in
more detail in Section 15.2 “Process Model”.
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Appendix D 2
Video Animation of the Plant Structure for a Baked Goods Manufacturer
(Bahlsen in Barsinghausen, Germany)
Sample Scene
In this case, the special goal was to functionally improve the existing building structure, the plant infrastructure, the logistic processes and the outdoor facilities. Moreover, in combination with the upcoming renovations and energetic improvements to
parts of the facade, a superior design for the plants presentation in terms of aesthetics, lighting and materials was desired. The storyboard, which was agreed upon with
the client, focused on visually conveying these new qualities to employees and visitors along with alternative facade designs and the impact of the plant’s corporate
identity from up close and from a distance.
Incorporating the video animation into the synergetic planning process is described in
more detail in Section 15.2 “Process Model”.
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Appendix D 3
Video Animation of a Car Radiator Factory
(Modine in Wackersdorf, Germany)
Overview of a Factory Structure
In this video animation Appendix D3 provides an example of a modular and changeable assembly factory for car radiators. Goals included:
 highly changeable processes, systems and buildings,
 the possibility to expand without disrupting production, and
 a high degree of reusability.
This was made possible through span widths of 18 and 36 m, an 8 m hall ceiling
clearance and easily moved workstations.
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Appendix D 4
Video Animation of a Tire Factory
(Barum Continental in Otrokovice, Czech Republic)
View of the Production
This factory for high-speed tires combines the pre-assembly, vulcanization and quality inspection under one roof. The large span widths along with fully integrating management in an in-house office building facilitate a high level of transparency for all of
the processes and good communication.
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