Concept Of Facilities Planning And Plant Layout Computer Science Essay

Concept Of Facilities intend And Plant Layout Computer acquirement EssayBackground of the fussToday s manufacturing industry is go about conundrums that have been growing in size and complexity over the delay several years. As a result, there is an immediate need for procedures or techniques in solving conglomerate problems encountered in today s manufacturing electron orbit without extended shutdown s or expensive modifications ( Clark ,1996). hooeys intervention equipment and the facilities it operates understructure contribute to as much as 70 percent of the sum up cost of the manufactured merchandise (Tompkins et al, 1996).Facilities layout designing is severalize of facilities supply (Tompkins et al, 1996). It is the arranging of work office which, in habitual equipment casualty smoothes the way to approach facilities that have strong interactions. The main concern with the instal induction layout cooking is to reduce the cost of solids handling as poor actuals handling foot pass on business problems. To stay competitive in todays market a company moldiness reduce cost by planning for the future tenseMaterial handling cost is a indirect costs and both company wants to reduce this indirect cost and it constitutes a major helping of indirect costs in a eagerness Therefore plain small improvements in secular handling costs makes a round reduction in total indirect costs. The cost of material pass is a function of the distance the material is moved amid divisions called departments in a manufacturing ease. To reduce material handling costs, it is essential to have an optimum arrangement of departments to minimize the total distance traveledTompkins (1982) estimated that betwixt 20% and 50% of operating expenses in manufacturing burn be attributed to instalment planning and material handling. Thus any cost saving in this expanse can contribute to the overall efficiency of the end harvest-time system. Due to its wide r ange of applicability, the readiness layout problem will continue to be the melodic theme of research for many years to come. Graph hypothesis and computerized bundle of facility layout is a powerful tool that allows experimentation with various manufacturing techniques and layout without actual implementation. base on the in a extravagantlyer place facts, it is obvious that layout optimization and improvement be ii tasks that are crucial to any facility planning and layout select.1.2 affirmation of problemJPM Automobiles ltd is an automobile comp integritynt manufacturing company set in Gurgaon Haryana. The problem domain in that company is the departments are not located to according to manufacturing bidding subroutinees which have towering interdependency are not located resolve to each early(a). This cause distance travelled by the material is high from one department to another department which result high material handling cost. Which affect the overall effici ency of the company.In response to the above problems, the need for facilities layout optimization is needed. This language proposes to use Systematic Layout grooming (SLP) as to improve the facility layout of the company by interpret theory and BLOCKPLAN software to improve the company performance. The company performance improvements are in terms of mathematical productivity increase, reduction in travelling cost and reduction in travelling distance.1.3 ObjectivesThe problem area in that company is of higher material handling, in- serve well inventory, poor interdependency of department and inflexibility etc. due to its indecorous layout. Based on the above fact the objectives of the report areTo endure a detailed literature review of the facility layout problems.To analyze the alert layout of the company and conduct cost synopsis of the real layout.To propose improvements in the existing layout by graph theory and BLOCKPLAN software.To conduct cost analysis of the exis ting and proposed layouts.Compare cost analysis of the existing and proposed layout by graph theory and BLOCKPLAN software1.3 Concept of Facilities Planning and Plant LayoutA facility planning is a complex and broad subject that covers several disciplines. It involves civil, electrical, industrial and mechanical engineers, as well as architects, consultants, managers and urban planners. Facilities planning can be carve up into twain components facilities fix and facilities design. Facilities location is about agreement of the facility on a specific plot of land with applaud to customers, suppliers and other facilities. Facilities design lie ins of the facility systems design, the layout design and the handling systems design. The facility systems consist of the structural systems, the environmental systems, the lighting/electrical systems and safety systems. The layout consists of all equipment, motorcarry and furnishings within the building structure. The handling system con sists of the mechanisms needed to satisfy the required facility interactions for a manufacturing base, the facilities layout, also called localize layout, consists of the employment areas, payoff related or support areas and personnel areas within the building. Facilities planning has bugger off a diminutive component for companies to keep up with the current market trends in the cobblers last a couple of(prenominal) years. In the past facilities planning was in the beginning considered to be a science. In todays competitive global marketplace, facilities planning has become a strategy, (Tompkins et al, 2003).1.4 Facility LayoutIn any plant, there are Brobdingnagian numbers of finite geometric areas i.e. toil, machine foundation area, space for inventory, design, production control and supervision are arranged on the floor space of the building. The problem of arranging these areas in an effective manner is the facility layout problemFrancis et al (2006) define, facility l ayout as a technique of locating machines, biddinges and plant services within the plant, so as to achieve the right metre and quality of product at the lowest possible cost of manufacturing.The facility layout problem is concerned with an arrangement of physical facilities, such as departments or machines, in certain areas to reduce a companys indirect costs. It has been estimated (Savsar 1991) that between 20 and 50% of the total operating expenses within manufacturing are attributed to material handling, which is forthwith related to facility layout. A poorly conceived layout can result in congestion and prohibitive material handling costs and, on the other hand, an effective layout can provide an environment for efficient production. Since indirect costs are the largest portion of a companys total operating cost, the objective of a facilities layout problem is to minimize both interdepartmental issues and the rearrangement costs of changing layouts between time periods. The se costs are a function of the amount of material take to the woods and the distance the material is to be moved.The main objective of the facility layout problem is to minimize overall cost, which is at a time related to material flow between departments. cosmopolitanly material flow is represented by the product of the amount of material and the distance the material is moved. The distance traveled is estimated development rectilinear distance between centroids of the departments .Constraints ensure departments do not carre quaternity and departments are of proper size. Many computer algorithms have been veritable for conniving layouts, mainly for the layout of departments within factories.Types of facilities layoutThere are four sheaths of plant layout from the full point of view of manufacturing carrefour layoutProduct layout is based on the doing date of part being produced on the line. Parts follow a fixed path through the production resources. In product layout, m aterials flow from one workstation to next adjacent workstation directly. This type of plant layout is useful when the production process is organized in a continuous manner.Advantages of product layoutSimple, smooth coherent flow lines result due to fixes sequence of operation.Small work in process inventories due to work from one process is fed directly into the next.Low cost of material handling, due to straight and short channel and absence of clogtracking.Total production time per unit is short.Since the machines are located so as to minimize distances between consecutive operations, material handling is reduced.Little scientific discipline is usually required by operators at the production line hence, training is simple, short, and inexpensive.Simple production planning control systems are possible.Less space is occupied by work in tour and for temporary storageDisadvantages of product layoutWhenever breakdown of one machine shekels the entire line in the presence of eno ugh manpower. lack of process flexibility, since the layout is determined by the product, a change in product design may require major alternations in the layout.Lack of flexibility in timing, as the product cannot flow through the line faster thence the slowest task can be accomplished unless that task is performed at several stations.Supervision is general, rather than specialized. relatively high investment is required, as identical machines (a few not fully utilized) are sometimes distributed on the line.Worker fatigue as workers may become bored by the endless repetition of simple tasks.Process layoutProcess layout is also called lineage shop layout in which the layout for a process department is obtained by sort out of machines according to function of machine centers. Orders for individual products are routed through the various machine centers to obtain the required processing. This type of plant layout is useful when the production process is organized in batches. Machin es are general purpose, within their general function area, so that a wide variety of products can be handled.Advantages of process layoutA high degree of flexibility exists relative to equipment or manpower allocation for specific tasks.Smaller investment in equipment as duplication is not necessary unless volume is large.The diversity of tasks offers a more(prenominal) interesting and satisfying occupation for the operator.Supervisors for each department become highly, conditioned about their functions.Better exercising of machines can result in few machines usedDisadvantages of process layoutLack of process efficiency as back tracking and long movements may occur in the handling of materials.Lack of efficiency in timing as workers must wait between tasks.Complications of production planning and controlWorkers must have broad skills and must be paid higher wages than assembly line workers.Comparatively large amounts of in process inventory as space and enceinte are tied up by work in process. bring down productivity as each course requires different setups and operator training. decided scene layoutFixed position layout is generally associated with large, bulky product such as assembly of ship building, aircraft etc. In Fixed position layout workstation are brought to the material. Fixed position layout is shown in fig.1.3Advantages of fixed position layoutMaterial movement is reduced, minimizes damage or cost of moving.Promotes job enlargement by allowing individuals or teams to perform the whole job.Continuity of operations and responsibility results from team. This reduces the problems of re-planning and instructing commonwealth each time a new type of activity is to begin. extremely flexible can accommodate changes in product design, product mix, and product volume.Independence of production centers allowing scheduling to achieve minimum total production time.Disadvantages of fixed position layoutIncreased movement of personnel and equipment may b e expensive. The necessary combination of skills may be difficult to find and high pay levels may be necessary.Equipment duplication may occur.Higher skill requirements for personnel as they are involved in more operations.General supervision required.Cumbersome and costly positioning of material and machinery.Low equipment utilization as equipment may be left at a location where it will be needed again in a few days rather than moved to another location where it would be productive.Product family layout / Cellular LayoutThe layout for a product family is based on the grouping of part to form product family. Groupings are determined by the operations needed to perform work for a set of similar items or part families that require similar processing. A part family is a set of separate that require similar machinery, tooling, machine operations and jig or fixtures. The split within the family normally go from raw material to finished move within a single cell.Advantages of cellular LayoutReduced in process inventoryIncrease operator expertiseImproved human relations, job enlargement tend to occur.Supports the use of general purpose equipmentIncreased machine utilization.Disadvantages of cellular layoutGeneral supervision required.Higher skills level required of employees than for product layout.Reduced shop flexibilityDepends on balanced material flow between product layout and process layout, otherwise buffers and work in process storage are required.Lower machine utilization than for process layout1.5 Layout name Methods and Computer PackagesIt is highly desirable that the optimum plant layout be designed. Unfortunately, the order of magnitude of the problem is so great that true system optimization is beyond current capabilities. The approach normally taken in solving the plant layout problem is to try to find a satisfactory solution. Previously, facilities layout problems were solved primarily by using iconic models. Then analytical approaches were develo ped.In general, plant layout problems can be solved by any of the following approaches accept mathematical procedures.Heuristics.Optimal.Graph theory.A number of different procedures have been developed to aid the facilities planner in designing layouts.These procedures can be separate into two main categories construction type and improvement type. Construction type layout systems basically involve developing a new layout from scratch. Improvement procedures generate layout alternatives based on an existing layout.Based on the above two procedures, many algorithmic approaches have been developed. Some of them are Systematic Layout Planning (SLP) procedure, graph-based construction method, programming, network, Tabu search, simulated annealing and genetic algorithm. Based on these approaches, many computer-aided layout routines have been developed. Some of them are CRAFT, COFAD, CORELAP, ALDEP, PLANET, MULTIPLE, BLOCPLAN.1.6 Methodology of dissertationThis dissertation is to be co mpleted in 3rd and 4th semesters of my M.Tech duration of four semesters. The methodology for this dissertation is stated in Figure 1.1Introduction literary works reviewSystematic layout planningFacility layout a case studyCompany ProfileAnalysisConclusionThe dissertation report is divided into seven chapters as shown in figure 1.3. The current chapter gives an introduction of Facilities Planning and Plant Layout, Layout Design Methods and Computer Packages. In this chapter is also introducing Background of the problem, Statement of problem, Objectives of the dissertationChapter 2 provides detailed literature review which would be through throughout the 3rd semester.This chapter covers the different type of facility layout problems and layout design method and commercial software available for solution of facility layout problems.Chapter 3 introduces the expand of Systematic Layout Planning (SLP) for generation of layout alternatives.Chapter 4 covers the company background. It cove rs the company profile, cheek structure of the company, products, esteemed customer and its manufacturing process and its policies.Chapter 5 presents the case study in which existing layout is analyzed and new layout is proposed by GRAPH theory and BLOCKPLAN software and also provides a detailed cost analysis of existing layout and proposed layout.Chapter 6 contains conclusion and future scope.