Comparative Study Of Craft And QAP Techniques Applied To ... - ijifr

Research Paper

Volume 2

Issue 11

July 2015

International Journal of Informative & Futuristic Research

ISSN (Online): 2347-1697

Comparative Study Of Craft And QAP Techniques Applied To Redesigning Of Layout For Cub-Board Manufacturing Paper ID Key Words Received On

IJIFR/ V2/ E11/ 038

Page No.

4180-4188 Subject Area

Business Studies

Activity Relationship Chart, Flow Analysis, Plant Layout, QAP, Systematic Layout Planning, Traditional Craft 13-07-2015

G. Bharathi1 G. Ambrish 2

Accepted On

25-07-2015

Published On

27-07-2015

Faculty, Master of Business Studies, Bangalore University, Bangalore, India Faculty, Master of Business Studies, Bangalore University, Bangalore, India

Abstract

This paper presents results of the competitive study of Computerized Relative Allocation of Facilities Technique (Craft) and Quadratic Assignment Problem (QAP) techniques applied to redesigning the layout for cub-board manufacturing process. The present layout for the manufacturing of the cub-board is studied using charting techniques namely: operation process chart, flow diagram and activity relationship chart. In the present layout it was observed that the movement of material was high leading to a material handling cost of Rs.2605/day. New layout was developed using systematic layout planning technique (SLP). Two alternative block plans were developed using Craft and QAP techniques. The material handling costs per day turns out to be Rs.1334/day and Rs.1289/day with the reduction of 48.79 percentage with Rs.1271/day and 50.51 percentage with Rs.1316/day for the alternatives developed of Craft and QAP respectively. Therefore reduction in the material handling cost through application of Craft technique is marginally higher than by the QAP technique. 1.

Introduction

With rapid increase of demand in cub-board Industries need to increase their potential in production and effectiveness to compete against their competitors. At the same time, the production process

www.ijifr.com Copyright © IJIFR 2015

4180


International Journal of Informative & Futuristic Research (IJIFR) Volume - 2, Issue - 11, July 2015 23rdEdition, Page No: 4180-4188 needs to be equipped with the ability to have lower cost with higher effectiveness. Therefore, the way to solve the problem about the production is very important. There are many ways i.e. quality control (QC), total quality management (TAM), standard time, plant layout to solve the problems concerning productivity. [1] According to many researchers plant layout is one of the ways to reduce the cost of manufacturing and increase the productivity. Also increase good workflow in production route. This research describes original plant layout, material flow analysis, which includes area and distance between department A and B. It was found that all the departments around the facility was far and time consuming in sending the product from one department to another thus causing delays in manufacturing. The present plant layout and the operation process movement of the material from department takes long line by causing interruption in the flow as well useless area of the plant. According to these problems, the researchers would like to analyze the way to solve such problem and find the way to improve the plant layout. The basic industrial layout planning (SLP) method is a systematic procedure to design plant layout from input data and activities to evaluation of plant layout. This method provides the new plant layout that improves the process flow through the plant and helps to decrease the material handling cost. The new plant layout was developed by two competitive techniques namely, Craft and QAP. The comparative study of both techniques provides the optimal material handling cost.

2. Literature Survey 







Anucha Watanapa [2], proposed to improve the plant layout of pulley’s factory to eliminate obstructions in material flow and thus obtain maximum productivity. The present plant layout and the operation process of each section have been investigated. The problem in term of material flow of each operation section was identified. The result showed that disassembly surface finishing and inspection sections should be allocated next to each section to make the good material flow. The new plant layout decrease the distance of material flow, which rises production. W.Wiyaratn [3], study plant layout of iron manufacturing based on the systematic layout planning pattern theory (SLP) for increased productivity. The detailed study of the plant layout such as operation process chart, flow of material and activity relationship chart has been investigated. The new plant layout has been designed and compared with the present plant layout. The SLP method showed that new plant layout significantly decrease the distance of material flow from billet cutting process to ware house. Pinto Wilsten [4], experiments application of different heuristic approaches to a real facility layout problem at a furniture manufacturing company. All the models are compared (Graph Theory, CRAFT, BLOCPLAN, Optimum Sequence) here a number of parameters of interest are employed. The experiment shows that formal layout modeling approaches can be effectively used to solve real problems faced in industry, leading to significant improvements. Saifallah Benjaafar [5]addresses the problem of designing flexible plant layouts for manufacturing facilities where product demands are subject to variability. A flexible layout is one that maintains low material handling costs despite fluctuations in the product demand levels. Optimal and heuristic methods (CRAFT) are presented for generating flexible layouts and determining flow allocations under various design and operation assumptions.

G. Bharathi, G. Ambrish :: Comparative Study Of Craft And QAP Techniques Applied To Redesigning Of Layout For Cub-Board Manufacturing

4181


International Journal of Informative & Futuristic Research (IJIFR) Volume - 2, Issue - 11, July 2015 23rdEdition, Page No: 4180-4188 











R. Jayachitra [6], Study the suitability of a virtual cellular layout (VCL) along with an existing functional layout (FL) of an industry and a classical cellular layout (CL), if considered for implementation. To identify the suitability of a particular layout in a given environment, a typical manufacturing system is modeled using the WITNESS 2006 simulation software. The results from the simulation experiments indicate that the performance of virtual cellular manufacturing is often relatively superior to that of a functional layout. Uttapol Smutkupt [7], Proposed an integrated mathematical approach which allows a more detailed layout planning by simultaneously determining machine arrangement and transportation paths. This Facility can be adopted even though if the entire layouts have irregular shapes and sizes. Nittaya [8] designed the Cellular Manufacturing Layout (CML) for a selected group of product for Electronic Manufacturing plant (EMP) based on Systematic Layout planning (SLP) and selected the best layout using Analytic hierarchy Process (AHP). The process layout used early was not suited for Electronic Manufacturing plant due to high volume and high variety environment. R.D. Vaidya et.al [9], proposed new plant layout using CRAFT (Computerized Relative Allocation of Facilities Technique) which decrease the distance of material flow and transportation cost which increases production. Kamran Forghani et.al [10], proposed an integrated layout model for intra and inter department layout using QAP to evaluate material handling cost by considering design factors such as aisle distance, single/ multi row intra department layout and mixed-integer linear programming was formulated to minimize the total material handling cost using heuristics method. Meir J. Rosenblatt et.al [11, 12, 13], proposed Quadratic Assignment Problem which uses distance assignment problem formulation and solved using LP code. Then heuristic algorithm was used for obtaining reduced cost of the DAP solution and compares the solution with various algorithm like CRAFT, Biased Sampling, FLAC, DISCON, FATE TAA, DAP!, DAP2 and the optimal known values were taken from Burkard 1984, Wilhelm and Ward 1987.

3. FUNDAMENTALS OF SLP, CRAFT AND QAP 3.1 Systematic Layout planning (SLP) SLP is a tool used to arrange a workplace in a plant by locating two areas with high frequency and logical relationship close to each other’s. The process permits the quickest material flow in processing the product at the lowest cost and least amount of handling. The data were collected and the number of departments for manufacturing was counted in terms of direction of raw materials and product. The process chart, flow of material and activity relationship chart have been used in analysis. The problem of plant was determined and analyzed through SLP method to plan the relationship between the departments and area. The framework of SLP is shown in Fig1. Based on the data such as route, support, and relationships between material flow from- to chart and activity relation chart are displayed. From the material flow and relationship activity in production, the relation between each department can be observed. Then the results were drawn through the comparison between the existing manufacturing process and the proposed way.


4182


International Journal of Informative & Futuristic Research (IJIFR) Volume - 2, Issue - 11, July 2015 23rdEdition, Page No: 4180-4188

Data at P, Q, R, S, T level and activities

1. Material Flow

2. Activity relationship

3. Relationship Map

5. Available space

4. Needed Space

6. Relationship map of spares

8. Practical Implication

7. Consideration for changes

Plan A

Plan c Plan B

9. Results evaluations Choose the Plant Layout

Figure 1: systematic layout planning procedure (SLP) by Muther 1961. [14]

3.2 CRAFT (Computerized Relative Allocation of Facilities Technique) uses a pair wise exchange to develop a layout (Buffa et al., 1964; Hicks and Lowan, 1976). CRAFT does not examine all possible pair wise exchange before generating an improved layout. The input data includes dimensions of the building and facilities, flow of material or frequency of trips between facility pairs and cost per unit load per unit distance. The product of the flow (f) and distance (d) provides the cost of moving materials between two facilities. The cost reduction is then calculated based on the pre and Post Exchange material handling cost contribution. The input data for CRAFT is entered and the initial cost for the current layout is first calculated. This cost can be reduced using a pair wise comparison. 3.3 QAP (Quadratic Assignment Problem) this formulation, originally suggested by Koopmans and Beckmann (1957) [15], assigns n facilities to mutually exclusive sites (locations). The layout problem considered here assumes that each facility consumes the same area, and so any facility can be assigned to any site. The objective function involves minimizing total material handling cost (i.e. cost incurred by the flow of material among facilities). The overall minimum material handling cost is usually modeled by minimizing the product of interdepartmental flow and distance.

4.

Analysis Of Existing Plant Layout

The size of the manufacturing department is shown in Table 1 and block of existing layout is shown in figure 2. According to the original plant layout, the flow of material and material handling equipment could be discussed as follows:


4183


International Journal of Informative & Futuristic Research (IJIFR) Volume - 2, Issue - 11, July 2015 23rdEdition, Page No: 4180-4188 Table 1: Size of The Manufacturing Department

Department Area-required Area-defined D1 625 625 D2 625 625 D3 625 625 D4 625 625 D5 625 625 D6 625 625 D7 1250 1250 The Figure below shows the Existing layout of the cub-board manufacturing facility with the material handling cost of 2605/day.

Figure 2: Existing Layout Of Cub-Board Manufacturing With Material Handling Cost Of 2605/Day.

A. Flow of Materials Raw Materials were carried from long distance consumes much of time and energy, resulting in high cost, wastage of time and energy. B. Material handling The material handling was through pallet trucks’ carrying by hand was used to move long distance from department A to B was not flexible. Also there was a chance mishandling of components will causes damage to the costly high precision component.

5.

Analysis of plant layout based on SLP

According to the study, the manufacturing process was found that distance travelled could be reduced for moving the materials from one department to other department. The way to improve the plant was to apply SLP method to make the work flow continuous by arranging the important sequence of manufacturing. Therefore relationship of each activity in closeness area was considered, to make the relationship of each activity in graph called from- to chart was used which is shown in fig 3, and the closeness value are defined as A= absolutely, E= especially important, I= important, O=ordinary closeness, U=unimportant.


4184


International Journal of Informative & Futuristic Research (IJIFR) Volume - 2, Issue - 11, July 2015 23rdEdition, Page No: 4180-4188 Table 2: Relationship Diagram Of The Cub Board Manufacturing Company.

Raw material stores Cutting and shaping Welding Painting Assembly Inspection Dispatch

1

2

3

4

5

6

7

-

A

I

I

E

U

X

-

E -

U E -

O U E -

O I I E -

X X X U E -

Table 3: Relationship Index

Rating Definition A absolutely E especially important I important O ordinary closeness U unimportant X undesirable The important sequence of each activity was rearranged from the most important one to the least important one. The intensity of flow from one activity to another was developed. The details for each activity were described in Table 3, as follows Raw material stores Cutting and Shaping Welding Inspection painting Inspection Assembling Inspection Dispatch

Figure 3: operation process flow chart for cub board manufacturing

The figure below shows the graphical representation and flow diagram of the cub board manufacturing process.

D A

B

C

E

E

E Figure 4: flow diagram of the cub board manufacturing process


4185


International Journal of Informative & Futuristic Research (IJIFR) Volume - 2, Issue - 11, July 2015 23rdEdition, Page No: 4180-4188 6. Simulation Results A proposed Block plan of cub-board manufacturing is tested using both Craft and the QAP techniques. The simulation results shows that both the techniques are provide the feasible solution. Therefore reduction in the material handling cost through application of Craft technique is marginally higher than the QAP technique. The Figure below shows the proposed layout of the cub-board manufacturing facility using craft with the optimum material handling cost of 1=1334 /day.

Figure 5: Optimal Layout Using Craft Has Material Handling Cost Of 1334/Day

Init. Cost 1776.54 Index 1 2 3 4 5 6 7

Init. Seq. 1 5 7 3 4 2 6

Iterations Iterations 1 2 3

3 Type Switch: Switch: Switch:

Action 3 and 6 1 and 6 4 and 6

Cost 1622.506226 1522.628052 1338.682129

Figure 6: Step By Step Exchange By CRAFT

The Figure below shows the Proposed layout of the cub-board manufacturing facility using QAP technique with the optimum material handling cost of 1289/day.

Figure 7: Optimal layout using QAP has material handling cost of 1289/day


4186


International Journal of Informative & Futuristic Research (IJIFR) Volume - 2, Issue - 11, July 2015 23rdEdition, Page No: 4180-4188 Best Obj.: Search time: Runs: Complete: Stop Interval:

**

Current Sol. with 1289.177 Improvements 2.625 seconds Enum 2 Imp.: 46 100% 1000

Sorted Feasible Solutions Run Obj. 19 1289.17761 46 1289.17761 17 1432.39318 7 1533.14013 6 1650.25793 1 1776.54199

x1 2 2 2 2 4 1

x2 5 5 5 5 5 5

x3 6 6 6 7 7 7

x4 4 4 3 3 3 3

44

x5 1 1 1 1 1 4

x6 3 3 4 4 2 2

x7 7 7 7 6 6 6

Figure 7: Step by step exchange by QAP

7. Conclusion The increase demand of cub board sales requires faster production process equipped with lower production cost, reduced production time with higher effectiveness. Form the study it was found that plant layout reduces the cost of manufacturing and increase production. Such that the new plant layout was developed using systematic layout planning technique (SLP) and two alternative block plans were developed using Craft and QAP techniques. In the present layout it was observed that the movement of material was high leading to material handling cost of Rs.2605/day. The material handling costs per day turns out to be Rs.1334/day and Rs.1289/day for the alternatives developed by Craft and QAP respectively. Therefore reduction in the material handling cost by applying Craft technique is marginally higher than by applying the QAP technique.

References [1] S.Tenwang et al., “ Productivity improvement for Lamp Manufacturing a dissertation for Master’s degree in Manufacturing system engineering school of engineering.” King Mong kut’s university of technology Thonburi, 1991. [2] Anucha Watanapa, Phi chit Kajondecha, Patcharee Duangpitakwong, and Wisitsree Wiyaratn, Analysis Plant Layout Design for Effective Production. International Multiconference of Engineers and Computer scientists (IMECS 2011) Vol II, Hong Kong. [3] W. Wiyaratn, and A. Watanapa, Improvement Plant Layout Using Systematic Layout Planning (SLP) for Increased Productivity. World Academy of Science, Engineering and Technology 72 2010. [4] Pinto Wilsten, Layout Design of a Furniture Production Line Using Formal Methods. Journal of Industrial and Systems Engineering Vol. 1, No. 1, pp 81-96, 2007. [5] Saifallah Benjaafar, Design of Flexible Plant Layout. Department of Mechanical Engineering University of Minnesota, 2010. [6] R. Jayachitra and P. S. S. Prasad, Design and selection of facility layout using simulation and design of experiments. Indian Journal of Science and Technology, Vol. 3 No. 4 (Apr. 2010), 437-446. [7] Uttapol Smutkupt, and Sakapoj Wimonkasame, Plant Layout Design with Simulation. Proceedings of the International MultiConference of Engineers and Computer Scientists 2009 Vol II, IMECS 2009, March 18 20, 2009, Hong Kong. [8] Nittaya Ngampak, Busaba Phruksaphanrat, (2011),” Cellular Manufacturing Layout Design and Selection: A Case study of Electronic Manufacturing service Plant”, Proceedings of the International MultiConference of Engineers and Computer Scientists 2011,Vol II.


4187


International Journal of Informative & Futuristic Research (IJIFR) Volume - 2, Issue - 11, July 2015 23rdEdition, Page No: 4180-4188 [9] R.D. Vaidya, P.N. Shende et.al(2013), “Analysis Plant Layout for Effective Production”, “ International Journal of Engineering and Advanced Technology”, Vol II. [10] Kamran Forghani, Alireza Arshadi khamseh et.al (2012),” Integrated quadratic assignment and continuous facility layout problem”,” International Journal of Industrial Engineering Computations, 787–806. [11] Meir J. Rosenblatt, Boaz Golany, (1990),”A distance assignment approach to the facility layout problem”, “European Journal of Operational Research 57,253-270. [12] Burkard, R.E, (1984),”Quadratic Assignment Problem”, European Journal of Operational Research 15, 283-289. [13] Wilhelm, M.R., Ward, T.L (1987),”Solving Quadratic Assignment problem by Simulated Annealing”,”IIE Transactions 19, 107-119. [14] M. Khanswan and C. Poowarat, “A study on plant layout improvement”: A case study at kritchai Mechanical Company Ltd., A project for Bachelor’s degree in Industrial Engineering, Faculty of Engineering, Thannasa University, 1999. [15] Koopmans, T.C., and Beckmann, M. (1957), "Assignment problems and the location of economic activities", Econometrica 25, 53-76.


4188

Comparative Study Of Craft And QAP Techniques Applied To ... - ijifr

Recommend Documents