Industrial Engineering Lab

Transcription

1 NATIONAL INSTITUTE OF TECHNOLOGY CALICUT PROCESS LAYOUT DESIGN USING THE PROCESS LAYOUT PLANNING SOFTWARE PACKAGE Industrial Engineering Lab Name of Student: Lab Sub-Group: Registration No.: Date of Experiment: Date of Submission: Marks: Signature of Evaluator:

2 Learning outcomes Create awareness on the importance of arrangement of facilities in a plant area Ability to create a process layout based on different input data using the layout planning software package Create an awareness on customising a layout Create an awareness on the application of meta-heuristic as a solution procedure for a mathematical programming problem

3 PROCESS LAYOUT DESIGN USING THE PROCESS LAYOUT PLANNING SOFTWARE PACKAGE 1. INTRODUCTION Plant layout is the most effective physical arrangement, either existing or in plans of industrial facilities, i.e., arrangement of machines, processing equipment and service departments, to achieve greatest co-ordination and efficiency of 4 M s (Men, Materials, Machines and Methods) in a plant. Layout problems are fundamental to every type of organization/enterprise and are experienced in all kinds of concerns/undertakings. The adequacy of layout affects the efficiency of subsequent operations. It is an important pre-requisite for efficient operations and also has a great deal in common with many problems. Once the site of the plant has been decided, the next important problem before the management of the enterprise is to plan suitable layout for the plant. In the words of Mallick and Gandreau, Plant layout is a floor plan for determining and arranging the designed machinery and equipment of a plant, whether established or contemplated, in the best place, to permit the quickest flow of material, at the lowest cost and with the minimum handling in processing the product, from the receipt of raw material to the shipment of finished product. Need of Plant layout: Many situations give rise to the problem of plant layout. Two plants having similar operations may not have identical layout. This may be due to size of the plant, nature of the process and management s calibre. The necessity of plant layout may be felt and the problem may arise when: There are design changes in the product There is an expansion of the enterprise. There is proposed variation in the size of the departments.

4 Some new product is to be added to the existing line. Some new department is to be added to enterprise and there is reallocation of the existing department. A new plant is to be set up. Common type of plant layout Fixed position layouts: For end-items that are large and difficult to move Process layouts: Similar types of operations are grouped into functional work area or departments Product layout: All the necessary operations for producing a product are arranged in a sequence called line a production line, assembly line or flow line Features of process layout Can readily process any product that require work in any of the departments, regardless of the production volume and routine sequence of product Production output can be increased or decreased, new products can be added, and old one can be dropped, all without changing the basic departmental layout of the facility Number of possible routing is large and many of them require moving material over long distances a non-value adding activity Requires considerable effort for scheduling, routing, sequencing, and tracking of jobs Material movement is not continuous stop-and-go of work Jobs must wait until jobs completed according to schedule job waiting and hence large WIP Jobs waiting in each department are for different end-items, so machines have to set up for each job Large throughput time Job routed through several operations can take weeks or months to complete even though actual value-added processing take only hours or minutes The layout is flexible but inefficiency and waste exists in terms of time, material handling, defects and inventory

5 Suitable when the product mix is primarily of small-quantity, custom-designed, or oneof-a-kind 2. OBJECTIVES To develop a layout for the given production system and analyse different scenarios of the problem. Use the software package for layout planning. 3. FEATURES OF LAYOUT PLANNING SOFTWARE Layout planning software package allows the user to specify the locations of departments or facilities and calculates material handling cost for the proposed layout. Also, this package can generate random layout and the respective cost for material handling can be calculated. This package uses rectilinear measure and assumes unit cost for transporting unit item for unit distance. The Stand-alone version of the software package uses MATLAB codes for developing a good layout showing relative location of departments. The codes are for the Simulated Annealing (SA) algorithm of the Quadratic Assignment Formulation of the layout problem. Rectilinear distance measures are used and unit size departments are assumed. However, the package displays the solution with actual size of department. Also, the package allows using aisles between departments. The graphical output of the package permits the rearranging of the department (swapping of two departments), and orientation of departments to meet the practical requirements. The material handling cost of the generated layout is displayed immediately. Thus, this package helps the layout designer to choose appropriate layout. 4. PROBLEM STATEMENT Consider a production system where the path of flow of material is different at different times and the general flow nature for the system is as Shown in Fig.1. Jobs required to be processed in the production system are belonging to any of the A, B, C, D, E, or F category. The nature of flow of material shows the sequence in which a particular job visits various departments for its processing requirements. This production system consists of 12 departments such as Saw, Turn, Mill, Drill, Assembly, Paint, Weld, Grind, Bench Mould, Cast, Automatic screw machine, and Clean. The space requirements for these departments are given in Table 1.

6 3m 4m 3m 4m 3m 4m 3m 4m Saw Turn Mill Drill Assembly Paint Weld Grind Bench Mould Cast Automatic screw machine Clean National Institute of Technology Calicut A Saw Turn Mill Drill Assembly BSaw Mill Drill Paint C Clean Grind Mill Drill Paint D Bench mould Cast Weld Grind Turn Drill - Assembly E Clean Drill Mill Automatic screw machine Assembly F Saw Grind Drill Automatic screw machine Paint Fig 1: Job visiting sequence Table 1: Space requirement of departments The demand for various categories of jobs is provided in Table 2. Table 2: Demand forecast Job A B C D E F Monthly Production Rate in units Develop a layout for the production system which minimises the material handling cost. Use the given software package. Assume that the longest side of the department faces the aisle. (Aisle is provided between the rows.) The minimum aisle width is 2 m. A four row layout is required. Assume a metre space between departments when aisle is not present between departments. Note down the parameters used for obtaining the best layout. Write down every step of data entry and associated display in terminal during the best layout generation. Note down the best layout, distance matrix, flow matrix and the material handling cost. You can note down two material handling costs such as (i) the one corresponding to equal size departments, and (ii) the one corresponding to when the department size is as per the given sizes and the actual distance between them are measured on rectilinear

7 basis. Also calculate material handling cost from the distance matrix and flow matrix obtained from the software package and show the calculation steps. Develop an alternative layout under the following cases (i) swapping two departments of the best layout obtained, and (ii) changing the orientation of two departments. Show the generated layouts and the material handling costs. Generate best layout for the cases: (i) the departments are adjacent (No space between departments or aisles) (ii) the distance between the sides of the departments are two metre apart. Show the material handling costs and layout for the above cases. 5. PROCEDURE STEP 1: Open and Start Wamp Server application, from: Start > All Progarms>WampServer. Wait for Wamp Server to become online (turns Green when online, otherwise Red). STEP 2: Copy the URL to the web browser and press enter. URL: The page will take you to the home page of the LAYOUT PLANNING package page.

8 STEP 3: Click on the Create Layout tab on the home screen. STEP 4: In the Enter Department Detail head, enter the various dept. names (e.g. in this casedept_1 = Saw, Dept_2= Turn etc ) on the with their space requirements (Length & Breadth in meters, in this case 2 x3 and 2x3 respectively). Click on Add tab to insert new Dept. To delete a Dept click on cross icon in front of the corresponding Department. Double click on Save button to save the details entered, and click on Next tab.

9 STEP 5: In the Enter Product Details, name of the products (i.e. in this case A, B, C..) are entered with their corresponding demand (e.g. for A= 300, B+200 etc..) and visiting sequence in departments (e.g. in this case for product A it is: and for B it is: ). To add more products click on Add tab. Double click on Save tab after entering all products, and click Next tab. STEP 6: In Select Generation mode of Layout, select MATLAB Layout option by clicking on it. STEP 7: In the MATLAB Layout head, enter the details of : the number of rows required in layout (e.g. in this case it is 4), the number of iterations (e.g. In this case = 144 for 12

10 machines), the termination condition (e.g. preferred one is = 3), the cooling rate (e.g. preferred one is = 0.98). Click on the Connect With MATLAB Program link. STEP 8: Copy the computer generated command (e.g. In this case starting with start matlab no splash ) and paste it in Command Prompt of the windows to connect with the MATLAB. STEP 9: Wait for MATLAB to execute the iterations and after completion of the iterations the MATLAB window is automatically closed, Close the command prompt after this,then click Next tab. STEP 10: Now enter the details regarding aisles by selecting Insert Horizontal Aisles and Horizontal Distances Between Department option (e.g. in this case horizontal aisle=2 m & horizontal distance between depts.. = 1 m). Click on View Layout tab.

11 STEP 11: Generated layout is given below, generated after clicking View Layout tab. Material handling cost and Area is shown at the top, click on Flow Matrix tab and Distance Matrix tab to generate flow matrix and distance matrix respectively. STEP 12:Click on the two departments to interchange their position (the respective cost will also changes), STEP 13: Double click on a dept. to change its orientation.

12 6. RESULT (Instruction: The design of layout is available at the end of each case. So keep a printout of the following: (1) Layout, (2) Flow matrix and (3) Distance matrix for each case. ) 1. Best layout 2. After swapping 3. After changing orientation of department 4. The departments are adjacent (Best layout) 5. The distance between the sides of the departments are two meters apart (Best layout) MATLAB-Cost Area Material Handling Cost

13 7. INFERENCE References i. Francis, R.L., McGinnis, Jr., L.F. and White, J.A., Facility Layout and Location: An Analytical Approach, 2nd ed., Prentice-Hall of India, ii. Deb, K., Optimisation for Engineering Design: Algorithms and Examples, Prentice-Hall of India Pvt. Ltd, -use for simulated annealing procedure, iii. Madhusudanan Pillai, V., Irappa Basappa Hunagund, Krishna K. Krishnan, (2011), Design of robust layout for Dynamic Plant Layout Problems. Computers & Industrial Engineering, Vol. 61, pp