Applied Mechanics and Materials ISSN: 1662-7482, Vols. 110-116, pp 3952-3956 doi:10.4028/www.scientific.net/AMM.110-116.3952 © 2012 Trans Tech Publications, Switzerland
Online: 2011-10-24
Systematic layout Planning to Assist Plant Layout: Case study Pulley factory Anucha Watanapa and Wisitsree Wiyaratn Department of Production Technology Education, FIET, King Mongkut’s University of Technology Thonburi, Bangkok, Thailand 10140 e-mail:
[email protected],
[email protected] Keywords: Systematic layout planning; Plant layout; Pulley factory
Abstract. In this study, the application of a systematic plant layout planning (SLP) to assist the optimum design of process areas and locations is proposed. The number of machines and space requirement in pulley factory is determined. The operation process chart, flow of material and activity relationship chart have been investigated. The relationships between machines, operation sections and material flow are used to determine the suitable position of each activity. The SLP method has been employed to design the two alternative plant layouts and compare the performances between new layout and present layout in term of material flow. The new plant layout is modified by moving a disassembly and surface finish that significantly decrease the distance of material flow, so it is effective increasing production. Introduction The plant layout deals with the modified plant layout to offer the efficient work flow that provides high productivity. Several of methods such as Systematic Layout Planning (SLP), Computer program can apply to design plant layout. SLP is considered to be one of the alternative methods to design plant layout. SLP method is very interesting because it is a basic fundamental to apply for improving plant layout in all types of factories. Thus, SLP method is explored as a basic tool to design plant layout. Typically, the alternative plant layouts are designed and evaluated, after that the preferred alternative is identified and selected. To date, most of the previous investigations were to find favorable alternatives plant layout to obtain effective workflow, which provides the high production yield [1-4] Yujie et al. [1] applied SLP method to design the overall layout of log yards, that was examined the feasibility of SLP method in the layout of log yards. The result showed the good workflow and practical significance. In additional, the possibility of plant layout and installing aluminum foundry was studied [4]. As for the layout of plant, it was done in accordance with the step by step in SLP design and improved the productivity. Up to now, there are a few studies focusing on the determination of alternative plant layouts of based on simulation. For example, Terawattanarattikal et al. [2] studied the application of a simulation model to assist decision making on expanding capacity and plant layout design and planning of plastic packaging company. The research used Promodel as a tool to simulate; the resulting is compared the performance in term of % utilization, characteristics of WIP. Simulation model displayed various scenarios under the constraint such as area. The two alternative layouts have been designed, which the difference between two layouts are free space to place WIP and internal transportation, resulting layout 2 was preferred. In additional, the possibility of plant layout and installing aluminum foundry was studied [4]. As for the layout of plant, it was done in accordance with the steps in systematic plant layout design and improved the productivity. The computerized plant layout design using a hybrid heuristic model is used for integrating plant layout and material handling equipment selection under fuzzy environment. The optimization technique is also added to model to make the decision material handling equipment selection. The result showed the potential application of this model to obtain greater efficiency and productivity.
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It is clear from the above researches reveal that plant layout is possible way to improve the workflow in production route and make the factory to get more production. This article proposes with SLP method to design the plant layout of pulley factory, which was case study. The original plant layout, alternative plant layout, material flow analysis, including area and distance between unit operations, through pulley factory were studied. Systematic Layout Planning The principles of SLP SLP is a method of plant layout design of project, which described step -by -step of method. The information of P, Q, R, S, T, is product, quantity, route, support and production timing Data at P, Q, R, S, T levels and activities as the given basic elements. Many of tables, graphs, as analytical tools, carry out the design through the layout methods. The 1. Material flow 2. Activity relationship procedure of SLP is shown in Fig. 1 [3]. The SLP procedure can be used to develop a block layout and then a detailed layout for each planning. The SLP method shows the 3. Relational map relationship between the analysis of operation units, and requirement of area. The space areas requirement was determined. Then the 4. Needed space 5. Available space location of the operating units was drawn and the alternative plant layouts were designed. At last, the preferred plant layout was selected in 6. Relational map of space term of the increasing production and minimal cost adjustment. However, Plant layout must include not only the needs for the present 7. Considerations 8. Practical limitations for changes demand of production, but should also have design for future development or expansion. Plant layout designs The sequences of procedure following five Plan A Plan C steps were described. 1. The data were collected and the number Plan B of machines/ equipments for manufacturing was counted in terms of Choose the plant the direction for raw materials and 9. Result evaluation layout product. 2. The area of operation units such as Fig. 1. The procedure of SLP [3] machines/equipments was measured. 3. The operation process chart, flow of material and activity relationship chart have been used in analysis. 4. The problem of the plant was analyzed under the SLP method to design the plant layout based on the relationship between the equipments and the locations. 5. The plant layouts alternatives based on modifying consideration and practical limitations were drawn. 6. The preferred plant layout was selected in term of available space and convenient material flow, and compared to present layout.
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Scrap yard
Core making
Plant Layout Planning Furnace
Core store
Sand Mold
Sand Plant
Analysis of original plant layout This case is based on a Pulley factory, with a total production pieces that was based on customer’s order. The layout of factory is process layout. When using SLP method for the modified Pulley plant layout, the corresponding P, Q, R, S, T; is P- Pulley, size 2 rong 5 inch, Q- 320 pieces/day, R–Pulley process, S- safety department, and T-1005.35 min/production. The process layout and manufacturing process was shown in Fig. 2 and Fig. 3, respectively. The size of the equipment was relational to the area as shown in Table 1 and Table 2. Taken Sand
Core making
Sand Plant
Disassembly and surface finish
Melting Casting Mold
Pouring
Inspection Disassembly
Inspection
Packaging Surface finishing
Inspection
Fig. 2. Process layout of Pulley production Packaging
Fig. 3. Process layout of Pulley production Analysis of plant layout based on SLP According to the study of the manufacturing process, it was found that the long distance could be reduced for moving raw materials and the problem about useless area could be solved. The way to improve the plant was to apply SLP method to make the work flow continually by arranging the important sequence of the manufacturing. The initially, from to chart was studied, which showed the relationships between departments in each process. The entries in the chart represented the number of material between departments in each process of each day. Then the relationship of each activity in closeness area was considered to make the relationship of
Table 1. Relationship Between Equipment Size and Area Department
T otal working area (m² )
Sand plant
212.4
Sand mold by machine
386.56
Core store
25.92
Inspection
29.4
Disassembly surface finish
98.15
Melting casting
19.47
Inventory
2.25
Sand mold by hand
53.1
Raw material
48.01
Scrap yard
33
Sand ware house
35
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each activity, and the closeness value are defined as A =absolutely, E = especially important, I = important, O= ordinary closeness, U= unimportant. The details for each activity were described in Table 3, as follow. Table 2. The Amount and Sequence for Manufacturing The Pulley with Size 2 Rong 5 Inch Details Distance (m.) 1. Taken Sand by Bacho 8.85 2. Sand Mixing 3. Mixed sand and moving 7.3 4. Taken to core store 7.6 5. Lift bottom flask 6. Taken Sand 7. Making sand mold 8. Put core in the bottom flask 7. Taken to furnace 4.2 8. Tapping the molten metal to ladle 9. Moving laddle 13.2 10. Pouring 11. Waiting time for work piece cooling 12. Disassembly 21.3 13. Surface cleaning
-
14. Taken to inspection section
4.5
15. Inspection.
-
16. Move to inventory
-
17. Packaging
-
Total
66.95
Table 3. The Workflow of The Manufacturing Process in Double Stage Style
A. B. C. D.
Sand plant Core making Core store Sand Mold
Product
Per day
Routing
Pulley
320
A-B-C-D-E-F-G-H
E. Furnace F. Disassembly and surface finishing G. Inspection H. Inventory
Based on SLP method the modifying plant layout and practical limitations, a number of layouts were developed. The alternative plant layout displayed in Fig 5. The original plant layout represents A, while alternative plant layout represents B, C. The difference between two layouts is the location of a disassembly and surface finish and furnaces, for which disassembly and surface finish moving, is the effect to transport within manufacturing. However, the budget for moving the furnace is considered. Thus, the first alternative plant layout was possible to select. According to the analysis of the workflow for it was found that the distance from the moving out of the sand plant until inventory section was 63.10 m., reduced from 66.95 m. or reduced by 3.85 m.
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Table 4. From to Chart of Pulley with Size 2 Rong 5 Inch To From
A
B
C
A B C D E F G
D
E
F
G
H H
320
G
320
F
320 320
E D
311
C
301
B
301
H
A
Fig. 4. The sequence of activities in the manufacturing process. Conclusion This research presents plant layout and process of pulley production. The alternative plant layouts have been designed by SLP method. On the basis of SLP method, the sequence of work and work flow of pulley production was rearranged, which the rearrange layout can decrease flow of material, resulting in significance increased production. In additional, the reducing of material handling cost is observed. The proposed plant layout for moving disassembly and surface finish section is selected because it is suitable realistic and practical business.
A
B
References [1] Y. Zhu, and F. Wang, “Study on the General Plane of Log Yards Based on Systematic Layout Planning,” IEEE. Computer Society, vol. 4, 2009, pp. 92–95. [2] T. Prochanmarn, N. Suwadee, C. Chonthicha “Using Promodel as simulation tools to assist plant layout design and planning case study plastic packaging factory,” Songklanakarin Journal of Science and Technology vol 30, 2008, pp. 117-123.
C
Fig. 5. Plant layout of Pulley production
[3] M. Khansuwan 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, Thammasat University, 1999. [4] T. Sucharitkul et al., “The feasibility study and aluminium foundry plant layout design : a case study : Sathien Plastic and Fiber,” a dissertation for Master’s degree in Manufacturing Systems Engineering, School of Engineering, King Mongkut’s University of Technology Thonburi, 1999.
Mechanical and Aerospace Engineering, ICMAE2011 10.4028/www.scientific.net/AMM.110-116
Systematic Layout Planning to Assist Plant Layout: Case Study Pulley Factory 10.4028/www.scientific.net/AMM.110-116.3952
