An Approach For Layout Improvement Of Production Floor Based On Material Handling Cost (original) (raw)
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Improvement of Production Facility Layout With Systematic Layout Planning (SLP) Algorithm
2014
The purpose of this study is to rearrangement of production floor layout of facilities so as to minimize the distance and material handling costs at the time of production. The study was conducted on a company that is Flow Shop. The layout of the facility is based on the flow of the production process and product produced more than 1 type by using different machines. Placement facility layout resulting in irregular distances and large material handling costs. Factor plant layout will greatly affect the timeliness in each process. Sets the layout engine in such a way, is expected to reduce waiting time, and cost of the process of moving goods (material handling). The smaller the range of material handling, better layout. So that the production process will remain smooth and controlled until the last process. In this study, the total distance of the initial layout compared to the proposed layout there is a reduction in material handling distance. Material handling costs also decreased when compared to the initial layout with the proposed layout. In this study, the proposed layout which has been designed to be implemented in the company with socialization to the management about the advantages of the proposed layout, including the distance and material handling costs smaller. The design layout can still be developed with computer simulations to design a model of the real system with the goal of understanding the behavior of the system and evaluate it to improve system performance. The production process will get optimal results when supported production planning and control mature. Other factors are also very important to note in order to obtain optimal results in a production process is taking into consideration the layout of the production machine. SLP method could form the answer to minimize the distance and cost of material handling.
Improving factory layout under a mixed floor and overhead material handling condition
Journal of Manufacturing Technology Management, 2007
Purpose-In spite of having a number of general-purpose algorithms for solving plant layout problems, facility planners may still face a challenging task to adjust these algorithms to handle special, but not uncommon, layout problems. The purpose of this study is to propose a new method for addressing the impact of overhead space utilization on a plant layout solution. Design/methodology/approach-A new method for adjusting material flow under a mixed floor and overhead material handling condition is incorporated in an existing plant layout procedure. A case study involving the layout improvement in a lawn mower engine assembly facility is presented to illustrate the effectiveness of the proposed method. Findings-The analysis of solutions for the case study shows that the layout generated by the proposed modified material flow approach is a more economical solution. The case also shows, when it is important to optimize the use of space, the overhead space should be considered as part of any methodology for designing a good layout. Research limitations/implications-The proposed modified material flow approach can be applied to any facility where the use of overhead space for material handling is justifiable by limited floor space and/or by high cost of land. The proposed method can be applied to small to medium size problems with minimal computational effort. However, as the size of facility grows, the manual calculation becomes more time consuming and potentially erratic. Originality/value-This paper should be useful to both researchers and practitioners who deal with overhead space utilization in designing facility layouts.
Production Floor Layout Using Systematic Layout Planning in Can Manufacturing Company
—This paper presents an analysis on a production shop floor layout of a Can manufacturing company and the application of a systematic layout planning (SLP) procedure as an approach to solve the production shop floor layout problem. The relationship between machines, operation activities and material flow are used to determine the optimal location of each machine. SLP technique has been employed to design the two alternative production shop floor layouts and compare the performance between new layout and present layout in terms of material flow distance, traveling time, and traveling cost. The existing production process was inefficient, showing bottlenecks. The alternative layouts were developed based on minimum distance traveled between each pair of machine. It improved the company existing layout by reduced total movement traveled in production for material handling. The measurements covered the actual sizes of the layout and machines, activities between machines, distance between machines, and material flow between machines in the company. The proposed procedure is illustrated to be a viable approach for solving production shop floor layout design problem through a real-world case study. From the proposed two alternative layouts which are more economical, distance of the production flow can be shortened from 389.7m to 311.2m or 360.6m. The traveling time can be reduced from 901sec. to 750sec. and traveling cost can be reduced from 3.17 Birr to 2.98 or 2.19 Birr per each travel resulting increase in productivity.
A genetic algorithm for facility layout problems of different manufacturing environments
2004
This paper describes a genetic algorithm (GA) to solve the problem of optimal facilities layout in manufacturing systems design so that material-handling costs are minimized. The paper considers the various material flow patterns of manufacturing environments of flow shop layout, flow-line layout (single line) with multi-products, multi-line layout, semi-circular and loop layout. The effectiveness of the GA approach is evaluated with numerical examples. The cost performance is compared with other approaches. The results show the effectiveness of the GA approach as a tool to solve problems in facilities layout.
Utilisation of Evolution Algorithm in Production Layout Design
Applied Computer Science, 2017
The need for flexibility of layout planning puts higher requirements for utilisation of layout and location problem solving methods. Classical methods, like linear programming, dynamic programming or conventional heuristics are being replaced by advanced evolutionary algorithms, which give better solutions to large-scale problems. One of these methods are also genetic algorithms. This article describes the genetic algorithm utilisation in the production layout planningunder the terms of the digital factory concept. 1. REQUIREMENTS FOR THE PRODUCTION LAYOUT PLANNING Current pressure on rapid innovations in the factory places increasing requirements also on the manufacturing and logistics systems design from the point of view of reduced laboriousness, consumption of time and costs for the whole system of technological design and, at the same time, on growth of quality, complexity and ability to testify the outputs generated from this process (Mičieta, Biňasová & Haluška, 2014). Based ...
International Journal of Industrial Management, 2020
In the manufacturing company, an efficient production floor affects the productivity of the company. Thus, a well design production floor layout assists the company to achieve its objectives. In this regard, this study aims to design a new alternative production floor layout for the XYZ manufacturing company. The company facing the facility layout problem (FLP) where their workstation on the production floor was not located based on the activity-relationship. Thus, the company struggles to reduce the distance travel of their workers from one station to another by re-layout their production floor. The Systematic Layout Planning (SLP) method was used to determine the best new alternative layout for the company. Subsequently, the AnyLogic simulation software was utilized to test the effectiveness of the layout by using the number of steps as the parameter. As a result, it is found that the total number of steps of workers in the production floor can be reduced from 16,554 steps (in exi...
Optimisation of factory floor layout in a complex manufacturing process
This contribution describes the methods used in a factory floor optimization process. The manufacturing process involves approximately 140 machines and is concentrated around a group of multipurpose CNC machines. We have analysed the current state of the manufacturing system by constructing a discrete event simulation (DES) model. The factory manufactures approximately 30,000 different products and half-finished products using a corresponding number of different technical processes. Due to this complexity it is not feasible to manually construct a simulation model that would include every process, and a method for automated model construction was developed. The resulting DES model reads the data on open work orders, technical procedures and bills of materials from the company database. The model is used to develop optimisation methods and verify modifications needed for process optimisation. Final part of the contribution presents the optimisation problem handled in the project: minimisation of the total distance the products need to travel between the machines. By introducing some simplifications, the problem can be described as a quadratic assignment problem. We present a heuristic method that is based on force-directed graph drawing algorithms.
Use of Genetic Algorithm in Layout Design
Acta logistica
Within the design of production layout, the planners are often confronted with complex, sometimes conflicting demands and a number of restrictive conditions, which encourages their efforts to develop new, progressive approaches to the development of production layouts. The purpose of the innovative approaches in this field is to provide users with better, elaborated designs in less time, while they are able to implement various restrictive conditions and company priorities to the design. One of the ways is a use of metaheuristic algorithms by space solution optimisations of manufacturing and logistics systems. These methods have higher quality results compared to classical heuristic methods. Genetic algorithms belong to this group. Main goal of this article is to describe the Genetic Algorithm Layout Planner (GALP) that was developed by authors, and its experimental verification and comparison with results of the classical heuristic.
A Typical Manufacturing Plant Layout Design Using CRAFT Algorithm
In modern technological industrial era, the typical manufacturing plant consists of a large number of diversified activities interconnected as a unit with required communication facilities. The manufacturing plant layout area consists of various activity cells such as design office, manufacturing shops, assembly and inspection departments, administration and security locations etc., The fundamental goal of facility layout problem is to minimize the material flow costs by positioning the cells within stipulated area.The orientation and spatial coordinates of each cell is specified by FLP design and the orientation of each cell may be in horizontal or vertical position. In this paper,the manufacturing plant layouthas been designed by using Computerized Relative Allocation of Facilities Technique (CRAFT). JAVA programme has been developed to design the optimum plant layout by considering STEP file as input for developing an optimum plant layout.
Production Layout Planning Using Genetic Algorithms
Communications - Scientific letters of the University of Zilina, 2015
Globalisation of entrepreneurship has not only opened world markets but also global competition. The fundamental criteria for decisions on allocation of manufacturing capacities are currently not only costs (manufacturing, logistics, etc.), but mainly quality (of products, processes and services), flexibility (types of products, capacity, space, time) and a company´s innovative capability. Therefore the enterprise's facility layout needs to be more flexible to adapt to the rapidly changing environment. The need for flexibility of layout planning puts higher requirements for utilisation of layout and location problem solving methods. Classical methods, like linear programming, dynamic programming or conventional heuristics are being replaced by advanced evolutionary algorithms, which give better solutions to large-scale problems. One of these methods are also genetic algorithms. This article describes the genetic algorithm utilisation in the production layout planning.