StudyofSystematicLayoutPlanningSLPConceptinShoeFactorytoMaximizeEfficiency

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1 Global Journal of Researches in Engineering: G Industrial Engineering Volume 18 Issue 1 Version1.0 Type: Double Blind Peer Reviewed International Research Journal Publisher: Global Journals Online ISSN: & Print ISSN: Study of Systematic Layout Planning (SLP) Concept in Shoe Factory to Maximize Efficiency By Abu Jor, Md. Masud Rana, Tanvir Ahamed & Md. Elias Uddin Khulna University of Engineering & Technology Abstract- Systematic Layout Planning (SLP) is becoming very popular in the manufacturing industry for facility layout planning. But the application of this technique is not available in the shoe industry. The study aims at improving the plant layout of a shoe factory based on the SLP method. Analysis of the existing plant layout was made by studying the aspects like traveling distances, activity relationships, the flow of materials, and space and flow relationship diagram by using SLP tools. Alternative plant layout was designed and proposed based on evaluation and comparison with the existing one. The new approach of alternative plant layout was showing a32% decrease in the traveling distances of material and workflow, resulted in increasing the efficiency and decreasing the cost of the shoe factory. Keywords: shoe factory, plant layout, SLP, activity relationship, materials flow, efficiency. GJRE-G Classification: FOR Code: StudyofSystematicLayoutPlanningSLPConceptinShoeFactorytoMaximizeEfficiency Strictly as per the compliance and regulations of: Abu Jor, Md. Masud Rana, Tanvir Ahamed & Md. Elias Uddin. This is a research/review paper, distributed under the terms of the Creative Commons Attribution-Noncommercial 3.0 Unported License permitting all non commercial use, distribution, and reproduction inany medium, provided the original work is properly cited.

2 G Study of Systematic Layout Planning (SLP) Concept in Shoe Factory to Maximize Efficiency Abu Jor α, Md. Masud Rana σ, Tanvir Ahamed ρ & Md. Elias Uddin Ѡ Abstract- Systematic Layout Planning (SLP) is becoming very popular in the manufacturing industry for facility layout planning. But the application of this technique is not available in the shoe industry. The study aims at improving the plant layout of a shoe factory based on the SLP method. Analysis of the existing plant layout was made by studying the aspects like traveling distances, activity relationships, the flow of materials, and space and flow relationship diagram by using SLP tools. Alternative plant layout was designed and proposed based on evaluation and comparison with the existing one. The new approach of alternative plant layout was showing a32% decrease in the traveling distances of material and workflow, resulted in increasing the efficiency and decreasing the cost of the shoe factory. Keywords: shoe factory, plant layout, SLP, activity relationship, materials flow, efficiency. I. Introduction F ootwear is an emerging and one of the largest manufacturing sectors in Bangladesh and is set to become a major manufacturing hub for the global footwear market. It is highly favorable for the growth of this sector based on the availability of raw materials, workforce and geographical condition [1].It produces about 50 million pairs of shoe every year in Bangladesh [2]. There are about 30 modernized shoe factory involved in high-quality footwear production, with more than 2500 smaller footwear enterprises also present in the sector [3]. Recent export statistics indicate that the footwear sector is flourishing rapidly and further progression is expecting in the years to come. But due to improper plant layout, the production is hampered as most of the industries used old plant layout. Plant layout refers to the arrangement of facilities such as equipment, machinery, furniture etc. within the factory structure in such a way so as to have shortest flow of material at the minimum cost and with the least amount of handling in processing the product from the receipt of order to the shipment of the finished product [4].In the industry sector, it is most important to produce good quality products and meet customer requirement sunder existing resources such as employees, machines and other facilities. Design of facility layout is becoming a key basis of today s industrial units to manage all the resources, which can impact work efficiency. Appropriate planning and positioning of equipment s, Author α σ ρ Ѡ: Department of Leather Engineering, Khulna University of Engineering & Technology, Khulna-9203, and Bangladesh. abujorlekuet10@gmail.com Machines, materials, and other manufacturing supports and facilities is needed to create the effective plant layout [5]. Distances traveled by the components and personnel in a manufacturing system is one of the main factors for delays in manufacturing. Excess movement and transport is also a cause for extra costs and wasted energy [4].Systematic layout planning (SLP) method is a much known tool amend the existing layout and minimize the manufacturing delays, extra cost and waste of energy. The aim of this study was to analyze the current plant layout of a shoe factory using SLP technique [6] and provide a new approach for the design of effective plant layout for shoe industry through alternative layout development. II. Methodology The framework of this study is shown in Fig. 1. Based on the data such as department, area, support services, route, traveling distances, time, equipment and relationships between materials flow from to chart and activity relation chart are developed. Data Accumulation Flow Analysis Activity Relationship Analysis Space and Flow Determination Evaluation Comparison Figure 1: Simplified outline of SLP methodology The flow of materials and distances traveled in the existing plant layout, and activity relationship chart have been used to develop space and flow relationship diagram in current and proposed plant layout analysis. Then the results were drawn through the evaluation and comparison between the existing layout and the proposed way. a) Analysis of the Existing Plant Layout This stage deals with the collection of all the information and data that is essential to facilitate the 15

3 G 16 optimized plant layoutdesign. The study was conducted ina reputed footwear industry of Bangladesh and collected all necessary data. The enterprise has 500 skilled workers producing nearly 540,000 pairs of shoes per month with a production floor area is around square feet. i. Existing Plant Layout Block diagram of the existing plant layout was developed and shown in fig. 2 and fig.3. Figure 2: Block diagram of theexisting plant layout (1st floor) Cutting Closing/Swing PD Store D. Planning Wash R. Lasting Finishing Packaging Store + Unused Figure 3: Block diagram of existing plant layout (Ground floor) ii. Space Determination Space of each department of production and administration was determined using the converting method. This space needs to be applied for the implementation of each department bythe proposed plant layout.space for each department is shown in Table 1. Table 1: Space determination S/N Department Area (sq. /ft.) 1 Raw Material Storage Finished-goods storage Packaging Lavatories Office Worker Washroom Parking, Receiving and Shipping 1000 M. R. Office Wash Pu Chamber 8 PD Quality Control and Inspection Tool and Tool Cribs Lasting + Finishing PU plant Cutting 4500 iii. Material Handling Equipment The material handling system was not so developed to cop up with the current trend. Materials were handled manually, and the pathway was not so organized and results in extra effort and cost. Efforts are made in layout design to place the departments having more material movement close to each other to minimize material handling. The material handling system (MHS) is shown in Table 2. Table 2: Material handling equipment Among departments MHS Store-Cutting Manually Cutting-Stitching Manually Stitching-Lasting Manually Lasting- Finishing Manually iv. Activity Relationship Chart An activity relationship chart is one that shows the closeness rating among all pairs of departments or activities and their frequency of use [7]. There are six closeness ratings, i.e.a: Absolutely Necessary, E: Especially Important, I: Important, O: Ordinary, U: Unimportant and X: Undesirable. There is also six reasons for frequent use. The relationship of each activity in the closeness area and their frequency are shown in Table 3. Table 3: Activity relationship Activity Between Department Code/Reason Rating Directors Planning 6 A Directors Merchandising 6 A Directors PU mold 2 U Directors Store 4 E Directors Cutting 1 X Directors Closing 1 X Directors Lasting 1 X Directors Finishing 2 U Planning-PU mold 3 O Planning-Store 6 A Planning-Cutting 4 I Planning-Closing 1 X Planning-Lasting 1 X Planning-Finishing 2 U Merchandising-PU mold 3 O Merchandising-Store 3 O Merchandising-Cutting 1 X Merchandising-Closing 1 X Merchandising-Lasting 1 X Merchandising-Finishing 4 I PU mold-store 6 A PU mold-cutting 5 E PU mold-closing 5 E

4 G PU mold-lasting 2 U PU mold-finishing 1 X Store-Cutting 6 A Store-Closing 5 E Store-Lasting 3 O Store-Finishing 6 A Cutting-Closing 6 A Cutting-Lasting 1 X Cutting-Finishing 5 E Closing-Lasting 6 A Closing finishing 1 X Lasting-Finishing 6 A v. Space & Flow Relationship Diagram By relative positioning and functional area and others information from the previous analysis, a relationship diagram is developed in fig. 5. A chart on activity relationship is also displayed in figure 4.It was formulated by considering both quantitative data of distances traveled as well as the qualitative data of frequency collected from working personnel and supervisor. 1. Directors Conference room 2. Planning 3. Merchandising 4. Store 5. Cutting 6. Closing 7. Lasting 8. Finishing 9. PU Mould Figure 4: Activity relationship chart From Code Rating A E I O U X Reason Frequency of use high Frequency of use Midium Frequency of use low Information flow high Information flow Medium Information flow low Defination Absolutly Necessary Especially Important Important Ordinary Closeness Unimportant Undesirable Table 4: Distances traveled in the existing layout To Figure 5: Space & flow Relationship Diagram (existing) vi Flow of Materials Analysis Carrying of raw materials with long distances create waste in time and energy, resulting in high cost. A' from-to chart 'was developed as shown in Table 4. The obtained traveling distances was multiplied by the rating factor of the frequency of use to get the weighted value. Distance (Linear, ft.) Distance (Weighted, ft.) Director Planning Director Merchandising Director Store Director Cutting Director Closing Director Lasting Director Finishing Director PU Mould Planning Merchandising Planning Store Planning Cutting Planning Closing Planning Lasting Planning Finishing Planning PU Mould Merchandising Store Merchandising Cutting Merchandising Closing Merchandising Lasting Merchandising Finishing Merchandising PU Mould Store Cutting Store Closing

5 G 18 b) Design of New and Alternate Plant Layout The data from the analysis of existing plant layout was used in preparing new and alternate plant layout which was checked for optimum flow of work through the processes. i. Space and Flow Relationship Diagram Through activity relationship chart, space and flow relationship diagram of proposed layouts is developed and shown in the Figure 6. It was developed in a very simplified way than the existing one with considering the closeness rating and frequency of use. Store Lasting Store Finishing Store PU Mould Cutting Closing Cutting Lasting Cutting Finishing Cutting PU Mould Closing Lasting Closing Finishing Closing PU Mould Lasting Finishing Lasting PU Mould Total Figure 6: Space & flow Relationship Diagram ii. Flow of Materials Analysis The flow of materials in the newly developed plant layout reduced considerably due to optimization. The weighted value of traveling distances of flow of materials was decreased with a remarkable amount, and the results are displayed in table 5. Table 5: Flow of Materials Analysis From To Distance (m) Distance(weighted, ft) Director Planning Director Merchandising Director Store Director Cutting Director Closing Director Lasting Director Finishing Director PU Mould Planning Merchandising Planning Store Planning Cutting Planning Closing Planning Lasting Planning Finishing Planning PU Mould Merchandising Store Merchandising Cutting Merchandising Closing Merchandising Lasting Merchandising Finishing Merchandising PU Mould Store Cutting Store Closing

6 G Store Lasting Store Finishing Store PU Mould Cutting Closing Cutting Lasting Cutting Finishing Cutting PU Mould Closing Lasting Closing Finishing Closing PU Mould Lasting Finishing Lasting PU Mould Total iii. Proposed Plant Layout A block diagram of optimized plant layout was drawn in fig. 7 and fig.8. These are the desired alternative layout with the final look and output from the SLP technique. Figure 7: Block diagram of proposed plant layout (1stfloor) Store Closing/Swing D. Store R. Planning Wash Cutting Cutting Packaging Pu M. R. Office Wash Lasting Finishing Pu Chamber Figure 8: Block diagram of proposed plant layout (ground floor) iv. Evaluation Existing and proposed alternative layout was evaluated based on overall traveling distances [4]. Materials travelled in existing plant layout are ft. Where in proposed layout it is 9862 ft. on the weighted basis, this reduces the traveling distances about 32% in proposed layout which ultimately reduces the material flow cost 1.47 times. These reductions in flow minimization improve efficiency, productivity and idle time. Therefore, the proposed layout can be selected to maximize production. III. Results and Discussion A detailed study of the plant layout of the shoe factory such as its manufacturing processes, flow and traveling distances of information and materials, activity relationships, space and flow relationship diagram has been done. Long distances between closeness and frequent use of departments have been identified as the major problems of the current layout. A new alternative layout is proposed based on a simplified approach of SLP concept and compared with the current one and is shown in fig.9. Frequent and closeness departments positioned nearly in this layout. As a result total traveling distances per shoe production is reduced by 7428 ft., therefore reduces the travelling distances more than 32%. Figure 9: Comparison of existing & Proposed Plant Layout This indicates that the new alternative layout could considerably enhance the company s layout problems. IV. Conclusions Layout development of a plant is a common problem in our country. The aim of this investigation was to find out an approach to optimized plant layout in a shoe factory to reduce the flow of information and 19

7 materials, cost of materials handling, and hence increasing the productivity of the shoe industry. In this study, one alternative layout was developed, which reduced the traveling more than 32%. The new layout success fully increased the overall productivity of the facility. This approach can` help shoe manufacturers to develop more than one alternative and can choose the most effective one based on evaluation and comparison. Acknowledgment G 20 We thank the footwear industry for their support in data collection. References Références Referencias 1. Sayid Mia MA, Nur-E-Alam M, Ahmad F, Kamal Uddin M (2017) Footwear Industry in Bangladesh: Implementation of Six Sigma Methodology. Industrial Engineering & Management 6: 211.doi: / Sayid Mia MA, Nur-E-Alam M, Ahmad F, Kamal Uddin M (2017) Waste Management & Quality Assessment of Footwear Manufacturing Industry in Bangladesh: An Innovative Approach. International Journal of Engineering and Management Research Volume-7, Issue-4, July-August M. Ahamed, A Report on Leather and Leather Goods Industry of Bangladesh, JB Group Research Department, JBBC Corporation, Japan Bangla Business Center, O. Sutari, S. Rao, Development of Plant Layout Using Systematic Layout Planning (Slp) to Maximize Production A Case Study, International Journal of Mechanical And Production Engineering, 2014, Volume- 2, Issue S.A.A. Naqvi, M. Fahad, M. Atir, M. Zubair and M. M. She hzad, Productivity improvement of a manufacturing facility using systematic layout planning, Cogent Engineering (2016), 3: R. Muther, Systematic layout planning, Cahners Books (1984). 7. M.P. Groover, Work Systems: The Methods, Measurement & Management of Work, Prentice Hall, (2007).