Systematic layout planning

Abstract: The layout re-arrangement of fashion production lines realizing many small batches is rarely deployed according to well-known engineering procedures. In fact, it would often appear too complex to call a plant engineer for the proper layout design of such small production lines. Rather, it is preferred to apply empirical methodologies when considering, generally, factory know-how, general business needs, safety requirements, and so on. In the present work, the results of a fashion manufacturing line re-layout were compared by analysing the current situation with the solutions provided by a ʺhomemadeʺ company design, both through a systematic layout planning approach and a broader lean reengineering activity. In order to evaluate the effectiveness of each solution, the different alternatives were compared with the help of a discrete event simulator, analysing productivity, transportation times and costs. The result of the case study showed a slight advantage with the lean approach in considering such efficiency indicators. In addition, the lean production methods allowed the designers to identify some inefficiencies that other approaches could not see, since the latter did not focus on production in a holistic way.

Abstract: The proper use of physical space in a factory is an important operational factor since it establishes its primary organization as well as the material and information fl ow patterns, with long run impacts. In order to systematize an adequate plant layout, methods for macro-space planning such as SLP (Systematic Layout Planning) have been proposed to support the development of layout alternatives. However, due to the generation of sub-optimal solutions with different pros and cons, the process of determining the best layout alternative becomes critical to assure the company’s effi ciency and fl exibility, when facing different market scenarios. In this paper we propose the use of multicriteria decision support tools in conjunction with SLP. The multicriteria analysis proposed is illustrated in a case study from the automotive industry. The company analyzed is expanding its physical area to house new machines and optimize material fl ows. Nine different macro-layout alternatives were generated and the best overall alternative was evaluated in relation to seven criteria using AHP (Analytic Hierarchy Process).

Abstract: This research aims to design the factory layout of PT. Gunaprima Budiwijaya in order to increase production capacity. The problem faced by this company is inappropriate layout causes cross traffic on the production floor. The re-layout procedure consist of these three steps: analysing the existing layout, designing plant layout based on SLP and evaluation and selection of alternative layout using Simulation Pro model version 6. Systematic layout planning is used to re-layout not based on the initial layout. This SLP produces four layout alternatives, and each alternative will be evaluated based on two criteria, namely cost of material handling using Material Handling Evaluation Sheet (MHES) and processing time by simulation. The results showed that production capacity is increasing as much as 37.5% with the addition of the machine and the operator, while material handling cost was reduced by improvement of the layout. The use of systematic layout planning method reduces material handling cost of 10,98% from initial layout or amounting to Rp1.229.813,34.