Optimal facility layout and material handling network design

2019 ◽  
Vol 103 ◽  
pp. 237-251 ◽  
Author(s):  
Armin Klausnitzer ◽  
Rainer Lasch
Keyword(s):  
Network Design ◽  
Material Handling ◽  
Facility Layout

PERBAIKAN TATA LETAK LANTAI PRODUKSI INDUSTRI MEBEL MENGGUNAKAN METODE GRAFIK DAN ALGORITMA CRAFT

2020 ◽  
Vol 6 (1) ◽  
pp. 1
Author(s):  
Kuswanto Kuswanto ◽  
Juan Junius ◽  
Anita Christine Sembiring
Keyword(s):  
Operating System ◽  
Material Handling ◽  
Facility Layout ◽  
Integrated Planning ◽  
Furniture Manufacturing ◽  
Milling Machines ◽  
Material Handling Costs ◽  
The Cost ◽  
A Company ◽  
Research Show

Facility layout is integrated planning of the flow of a product in an operating system to obtain the most effective and efficient interrelation between workers, materials, machinery, and equipment as well as handling and transferring materials. A company engaged in furniture manufacturing has a problem in its production process, namely, the distance between machines is too far so that it affects the cost of handling materials. Distant workstations are found on profile machines, milling machines, measuring machines, cutting machines. Therefore, improvements must be made to the layout of facilities on the production floor so that facility layout is efficient and material handling costs are reduced. The problem-solving approach used is the Graph Method and CRAFT Algorithm. The results of the research show that material handling costs are reduced by 7.58% or Rp. 17,765 using the CRAFT algorithm.

Holistic simulation-based optimisation methodology for facility layout design with consideration to production and logistics constraints

2021 ◽  
pp. 095440542110173
Author(s):  
Enrique Ruiz Zúñiga ◽  
Erik Flores García ◽  
Matías Urenda Moris ◽  
Masood Fathi ◽  
Anna Syberfeldt
Keyword(s):  
Material Handling ◽  
Facility Layout ◽  
Holistic Approach ◽  
Multiple Attribute Decision Making ◽  
Layout Design ◽  
Analytic Hierarchy ◽  
Facility Layout Design ◽  
Multiple Attribute ◽  
Simulation Based ◽  
Optimisation Methods

Facility layout design is becoming more challenging as manufacturing moves from traditionally emphasised mass production to mass customisation. The increasing demand for customised products and services is driving the need to increase flexibility and adaptability of both production processes and their material handling systems. A holistic approach for designing facility layouts with optimised flows considering production and logistics systems constraints seems to be missing in the literature. Several tools, including traditional methods, analytic hierarchy process, multiple-attribute decision making, simulation, and optimisation methods, can support such a process. Among these, simulation-based optimisation is the most promising. This paper aims to develop a facility layout design methodology supported by simulation-based optimisation while considering both production and logistics constraints. A literature review of facility layout design with simulation and optimisation and the theoretical and empirical challenges are presented. The integration of simulation-based optimisation in the proposed methodology serves to overcome the identified challenges, providing managers and stakeholders with a decision support system that handles the complex task of facility layout design.

An Unequal-Sized Unidirectional Loop Layout Design Problem Considering Empty Vehicle Trip

2010 ◽  
Vol 37-38 ◽  
pp. 116-121
Author(s):  
Yu Lan Li ◽  
Bo Li ◽  
Su Jun Luo
Keyword(s):  
Material Handling ◽  
Design Principle ◽  
Facility Layout ◽  
Original Model ◽  
Layout Problem ◽  
Proposed Model ◽  
Loop Layout ◽  
Material Handling Costs ◽  
Loop Layout Problem ◽  
Better Than

In the facility layout decisions, the previous general design principle is to minimize material handling costs, and the objective of these old models only considers the costs of loaded trip, without regard to empty vehicle trip costs, which do not meet the actual demand. In this paper, the unequal-sized unidirectional loop layout problem is analyzed, and the model of facility layout is improved. The objective of the new model is to minimize the total loaded and empty vehicle trip costs. To solve this model, a heuristic algorithm based on partheno-genetic algorithms is designed. Finally, an unequal-sized unidirectional loop layout problem including 12 devices is simulated. Comparison shows that the result obtained using the proposed model is 20.4% better than that obtained using the original model.

scholarly journals Multi Objective Simulated Annealing Approach for Facility Layout Design

2018 ◽  
Vol 3 (4) ◽  
pp. 365-380 ◽  
Author(s):  
Safiye Turgay
Keyword(s):  
Simulated Annealing ◽  
Objective Function ◽  
Material Handling ◽  
Simulated Annealing Algorithm ◽  
Facility Layout ◽  
Layout Design ◽  
Local Optima ◽  
Facility Layout Design ◽  
Multi Objective ◽  
Annealing Algorithm

Facility layout design problem considers the departments’ physcial layout design with area requirements in some restrictions such as material handling costs, remoteness and distance requests. Briefly, facility layout problem related to optimization of the layout costs and working conditions. This paper proposes a new multi objective simulated annealing algorithm for solving of the unequal area in layout design. Using of the different objective weights are generated with entropy approach and used in the alternative layout design. Multi objective function takes into the objective function and constraints. The suggested heuristic algorithm used the multi-objective parameters for initialization. Then prefered the entropy approach determines the weight of the objective functions. After the suggested improved simulated annealing approach applied to whole developed model. A multi-objective simulated annealing algorithm is implemented to increase the diversity and reduce the chance of getting layout conditions in local optima.

A Pattern Recognition Approach for Manufacturing Facility Compaction by Machining Function Combination Using Flexible Manufacturing Modules

2003 ◽  
Vol 125 (4) ◽  
pp. 740-752
Author(s):  
Shahrukh Irani ◽  
Jin Zhou ◽  
Heng Huang
Keyword(s):  
Pattern Recognition ◽  
Flexible Manufacturing ◽  
Material Handling ◽  
Facility Layout ◽  
Integrated Approach ◽  
Machine Grouping ◽  
Function Combination ◽  
Machining System ◽  
Material Handling Costs ◽  
Space Requirements

Facility layout and flexible automation are two approaches for reduction of material handling costs and space requirements in a machining facility that have always been implemented independently of each other. This paper describes an integrated approach to compaction of existing machining facilities using machine grouping algorithms and multi-function machining centers, also referred to as Flexible Machining Modules (FMMs). First, we decompose a facility into a network of layout modules to reduce product travel distances and simplify material flow control. Then, subject to design feasibility, we identify those sets of machines in each module that could be replaced by multi-function FMMs that could be linked into a Flexible Machining System (FMS). The proposed approach uses a combination of pattern recognition and graph theory algorithms utilized for facility layout. The paper concludes with a description of a validation study conducted in an aerospace machining jobshop.

scholarly journals Genetic algorithm using a modified backward pass heuristic for the dynamic facility layout problem *

2011 ◽  
Vol 2 (3) ◽  
Author(s):  
Kazi Shah Nawaz Ripon ◽  
Kyrre Glette ◽  
Dirk Koch ◽  
Mats Hovin ◽  
Jim Torresen
Keyword(s):  
Genetic Algorithm ◽  
Material Handling ◽  
Manufacturing System ◽  
Industrial Robot ◽  
Facility Layout ◽  
Layout Problem ◽  
Facility Layout Problem ◽  
Dynamic Facility Layout Problem ◽  
Economical Consideration ◽  
Over Time

AbstractLayout planning in a manufacturing company is an important economical consideration. In the past, research examining the facility layout problem (FLP) generally concerned static cases, where the material flows between facilities in the layout have been assumed to be invariant over time. However, in today’s real-world scenario, manufacturing system must operate in a dynamic and market-driven environment in which production rates and product mixes are continuously adapting. The dynamic facility layout problem (DFLP) addresses situations in which the flow among various facilities changes over time. Recently, there is an increasing trend towards implementation of industrial robot as a material handling device among the facilities. Reducing the robot energy usage for transporting materials among the facilities of an optimal layout for completing a product will result in an increased life for the robots and thus enhance the productivity of the manufacturing system. In this paper, we present a hybrid genetic algorithm incorporating jumping genes operations and a modified backward pass pair-wise exchange heuristic to determine its effectiveness in optimizing material handling cost while solving the DFLP. A computational study is performed with several existing heuristic algorithms. The experimental results show that the proposed algorithm is effective in dealing with the DFLP.

scholarly journals FACILITY LAYOUT REDESIGN USING SYSTEMATIC LAYOUT PLANNING METHOD IN PT. PILAR KEKAR PLASINDO

2021 ◽  
Vol 16 (Number 1) ◽  
pp. 57-68
Author(s):  
Bambang Suhardi ◽  
Lulu Elvira ◽  
Rahmaniyah Dwi Astuti
Keyword(s):  
Material Handling ◽  
Facility Layout ◽  
Material Transfer ◽  
Layout Planning ◽  
Production Section ◽  
Systematic Layout Planning ◽  
Polyethylene Production ◽  
Material Handling Costs ◽  
Large Material ◽  
Alternative Designs

Good equipment and product design are meaningless if there is no good layout planning. Problems owned by PT. Pilar Kekar Plasindo occurs in the production of small polyethylene. This is because small polyethylene production has large material total transfer distance. Small polyethylene problems include the distance between stations, cross-movement, backtracking, and the broken machine that is still placed in the production section. These conditions make the material handling costs and distance large. Therefore, this research aims to produce a layout design of production facilities that can minimize the distance and cost of material movement. The method used in this study is Systematic Layout Planning (SLP). Three alternative designs were compared, and the second proposed facility layout was chosen because it can reduce the total cost of material transfer by 68.3% and reduce the distance of material transfer by 59.6% from the initial facility layout.

scholarly journals A new soft computing algorithm based on cloud theory for dynamic facility layout problem

2020 ◽  
Author(s):  
Mostafa Zandieh ◽  
Seyed Shamsodin Hosseini ◽  
parham azimi ◽  
Mani Sharifi
Keyword(s):  
Material Handling ◽  
Simulated Annealing Algorithm ◽  
Facility Layout ◽  
Planning Horizon ◽  
Test Problems ◽  
Layout Problem ◽  
Facility Layout Problem ◽  
Dynamic Facility Layout Problem ◽  
Material Handling Costs ◽  
Cloud Theory

This paper deals with dynamic facility layout problem (DFLP) in a plant which is concerned with determining the best position of machines in the plant during a multi-period planning horizon. The material handling costs and machines rearrangement costs are used to determine the best layout. In addition to positions of machines, the details of transportation such as type of transporters and sequence of transportation operations have a direct effect on MHC. Therefore, it is more realistic to consider the transportation details during DFLP optimization. This paper proposes a new mathematical model to simultaneously determine the best position of machines in each period and to plan the transportation operations. Minimizing sum of MHC and MRC is considered as the objective function. A new hybrid meta-heuristic approach has been developed by combining modified genetic algorithm and cloud-based simulated annealing algorithm to solve the model. Finally, the proposed methodology is compared with two meta-heuristics on a set of test problems.

scholarly journals Heuristics for the dynamic facility layout problem with unequal area departments

2008 ◽  
Author(s):  
◽  
Artak Hakobyan ◽  
Keyword(s):  
Material Handling ◽  
Facility Layout ◽  
Planning Horizon ◽  
Combinatorial Structure ◽  
Material Flows ◽  
Layout Problem ◽  
Dual Simplex Method ◽  
Data Set ◽  
Facility Layout Problem ◽  
Dual Simplex

The facility layout problem (FLP) is a well researched problem of finding positions of departments on a plant floor such that departments do not overlap and some objective(s) is (are) optimized. In this dissertation, the FLP with unequal area rectangular shaped departments is considered, when material flows between departments change during the planning horizon. This problem is known as the dynamic FLP. The change in material flows between pairs of departments in consecutive periods may require rearrangements of departments during the planning horizon in order to keep material handling costs low. The objective of our problem is to minimize the sum of the material handling and rearrangement costs. Because of the combinatorial structure of the problem, only small sized problems can be solved in reasonable time using exact techniques. As a result, construction and improvement heuristics are developed for the proposed problem. The construction algorithms are boundary search heuristics as well as a dual simplex method, and the improvement heuristics are tabu search and memetic heuristics with boundary search and dual simplex (linear programming model) techniques. The heuristics were tested on a generated data set as well as some instances from the literature. In summary, the memetic heuristic with the boundary search technique out-performed the other techniques with respect to solution quality.

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