Increasing the Efficiency of Robotic Manufacturing Systems by Layout Optimization

2015 ◽  
Vol 762 ◽  
pp. 283-290
Author(s):  
Bogdan Mocan ◽  
Darius Buna ◽  
Mircea Fulea ◽  
Stelian Brad
Keyword(s):  
Material Flow ◽  
Manufacturing Systems ◽  
Material Handling ◽  
High Efficiency ◽  
Facility Layout ◽  
Flow Path ◽  
Decision Matrix ◽  
Analytic Hierarchy ◽  
Volume Flexibility ◽  
Multi Criteria Evaluation

To achieve high efficiency in a robotic manufacturing system, an optimized layout arrangement and material flow path design are important due to the large percentage of product cost that is related to material handling, equipment positioning, material flow path, and products variety and volume (flexibility). Facility layout problem (FLP) can be considered as a multi-criteria problem due to presence of the qualitative criteria such as flexibility and the quantitative criteria for instance total cost of handling material. In this paper, we combined a well-known facility layout algorithm (CRAFT) with Analytic Hierarchy Process (AHP) technique and decision matrix method to facilitate a multi criteria evaluation. The proposed approach aims to incorporate qualitative criteria in addition to quantitative criteria for evaluating facility layout patterns. A case study on a robotic system for manufacturing plate type oil coolers reveals the effectiveness of the proposed approach.

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.

scholarly journals Usulan Perbaikan Tata Letak Fasilitas Terhadap Optimalisasi Jarak dan Ongkos Material Handling Dengan Pendekatan Systematic layout planning (SLP) di PT Transplant Indonesia

2018 ◽  
Vol 2 (1) ◽  
pp. 45
Author(s):  
Dede Muslim ◽  
Anita Ilmaniati
Keyword(s):  
Material Flow ◽  
Material Handling ◽  
Layout Design ◽  
Flow Path ◽  
Material Transfer ◽  
Layout Planning ◽  
Handling Cost ◽  
Material Handling Cost ◽  
Systematic Layout Planning ◽  
The Cost

Abstract – Unplanned layout and inefficient material flow between work units can lead to increased cost. PT Transplan Indonesia's current material flow path is inefficient with material flow distance 115.5 meters and material handling cost that has not been taken into account. This study aims to find out how big the role of facility layout design in cutting the distance of material transfer and pressing the cost of material handling. The method used in this research is Systematic Layout Planning (SLP) approach, which is comparing the distance of material transfer between initial layout with proposed layout. The results of this study indicate that the distance of the material flow path on the production floor with proposed layout changed to 71,7 meters, with material handling cost per meter reduced from Rp. 1,105,954 to Rp. 712,402 or decrease as much as 35%. Based on the results of the research, the layout of the proposal is considered more effective and efficient because it can reduce the distance of material transfer and reduce the cost of material handling on the packing/shipping floor.Keywords: Layout Design; Material handling cost; Systematic Layout Planning (SLP)

scholarly journals Monarch Butterfly Optimization for Facility Layout Design Based on a Single Loop Material Handling Path

Mathematics ◽  
2019 ◽  
Vol 7 (2) ◽  
pp. 154 ◽  
Author(s):  
Minhee Kim ◽  
Junjae Chae
Keyword(s):  
Material Flow ◽  
Material Handling ◽  
Facility Layout ◽  
Monarch Butterfly ◽  
Layout Design ◽  
Monarch Butterfly Optimization ◽  
Single Loop ◽  
Handling Cost ◽  
Material Handling Cost ◽  
The Given

Facility layout problems (FLPs) are concerned with the non-overlapping arrangement of facilities. The objective of many FLP-based studies is to minimize the total material handling cost between facilities, which are considered as rectangular blocks of given space. However, it is important to integrate a layout design associated with continual material flow when the system uses circulating material handling equipment. The present study proposes approaches to solve the layout design and shortest single loop material handling path. Monarch butterfly optimization (MBO), a recently-announced meta-heuristic algorithm, is applied to determine the layout configuration. A loop construction method is proposed to construct a single loop material handling path for the given layout in every MBO iteration. A slicing tree structure (STS) is used to represent the layout configuration in solution form. A total of 11 instances are tested to evaluate the algorithm’s performance. The proposed approach generates solutions as intended within a reasonable amount of time.

scholarly journals Amelioration of Capacity Constraints in Manufacturing Systems Using Alternate Production Sequence

2017 ◽  
Vol 5 (1) ◽  
pp. 73-92
Author(s):  
Dhagash Shah ◽  
Krishna Krishnan ◽  
Mukund Dhuttargaon
Keyword(s):  
Production System ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Facility Layout ◽  
Production Capacity ◽  
Capacity Constraints ◽  
Product Mix ◽  
Product Demand ◽  
Demand Changes ◽  
The Cost

Today’s market is in a constant flux of demand changes.  Due to this the product demand and the product mix continuously change from one time-period to the next.  For a company to be profitable and competitive, it has to ensure that all of its resources are optimally utilized.  These resources include facility layout, material handling, and production system.  Previous research has shown that the system state has to be identified prior to increasing capacity to mitigate the constraint.  As the demand and product mix change, a facility layout that was efficient can soon become inefficient or the cost of production and material handling increase.  This research evaluates usage of alternate part sequence as a means to eliminate or reduce production system constraints.  It focuses on reducing machine usage when the selected process sequence leads to production capacity constraints.

scholarly journals A Multi-Criteria Assessment of Manufacturing Cell Performance Using the AHP Method

2022 ◽  
Vol 12 (2) ◽  
pp. 854
Author(s):  
Zuzana Soltysova ◽  
Vladimir Modrak ◽  
Julia Nazarejova
Keyword(s):  
Manufacturing Systems ◽  
Objective Assessment ◽  
Performance Criteria ◽  
Research Approach ◽  
Cell Design ◽  
Analytic Hierarchy ◽  
Manufacturing Cell ◽  
Alternative Design ◽  
Multi Criteria Evaluation ◽  
Analytic Hierarchy Process Method

Research of manufacturing cell design problems is still pertinent today, because new manufacturing strategies, such as mass customization, call for further improvement of the fundamental performance of cellular manufacturing systems. The main scope of this article is to find the optimal cell design(s) from alternative design(s) by multi-criteria evaluation. For this purpose, alternative design solutions are mutually compared by using the selected performance criteria, namely operational complexity, production line balancing rate, and makespan. Then, multi-criteria decision analysis based on the analytic hierarchy process method is used to show that two more-cell solutions better satisfy the determined criteria of manufacturing cell design performance than three less-cell solutions. The novelty of this research approach refers to the use of the modification of Saaty’s scale for the comparison of alternatives in pairs based on the objective assessment of the designs. Its benefit lies in the exactly enumerated values of the selected criteria, according to which the points from the mentioned scale are assigned to the alternatives.

scholarly journals PERANCANGAN FASILITAS PABRIK TAHU UNTUK MEMINIMALISASI MATERIAL HANDLING

2012 ◽  
Vol 13 (2) ◽  
pp. 133
Author(s):  
MERRY SISKA ◽  
HENRIADI .
Keyword(s):  
Material Flow ◽  
Path Length ◽  
Material Handling ◽  
Facility Layout ◽  
Flow Analysis ◽  
Work Productivity ◽  
Material Flow Analysis ◽  
Layout Planning ◽  
Systematic Layout Planning ◽  
Three Stages

MERRY SISKA DAN HENRIADITeknik Industri, Fakultas Sains dan Teknologi, UIN Sultan Syarif Kasim Riau, PekanbaruLaman: [email protected]. Dhika Putra merupakan perusahaan yang bergerak dalam pembuatan tahu. Saat ini kondisi layout fasilitasproduksi dan kondisi fisik lingkungan kerja di perusahaan mengalami kendala. Penelitian ini bertujuan untuk merancangulang tata letak fasilitas pabrik pembuatan tahu yang dapat meminimalkan panjang lintasan material handling sertamenerapkan metode 5S untuk meningkatkan produktivitas kerja. Pendekatan yang digunakan pada perancangan ulangtata letak fasilitas pabrik adalah dengan menggunakan pendekatan Systematic Layout Planning (SLP) yang dapatdikategorikan ke dalam tiga tahapan, yaitu tahap analisis aliran material, tahap penelitian dan tahap proses seleksi.Sedangkan metode 5S terdiri dari beberapa tahapan untuk mengatur kondisi tempat kerja yang berdampak terhadapefektivitas kerja, efisiensi, produktivitas dan keselamatan kerja. Hasil penelitian ini menyimpulkan bahwa layout usulanyang terpilih untuk dijadikan layout akhir dalam penelitian ini menunjukkan penurunan panjang lintasan materialhandling yang cukup signifikan yaitu 45 m atau sekitar 19,2% lebih pendek dari layout awal. Berkurangnya panjang aliranmaterial handling layout yang terpilih juga dipengaruhi karena penataan lingkungan kerja dengan metode 5S.Kata kunci: material handling, tata letak fasilitas ����pabrik, systematic layout planning, metode 5SABSTRACTUD. Dhika Putra is a tahu manufacturing company. Currently, the company is having some problems in productionfacility layout and physical environment. This study aimed to redesign the facility layout of tahu manufacturing companyto minimize the path length of material handling and apply the 55 method to enhance work productivity. The approachused to redesign the plant facility layout is Systematic Layout Planning (SLP), which can be categorized in three stages,namely material flow analysis, research, and selection. While the 55 method consist of several steps to organize workplacecondition that affect on the effectiveness, eficiency, productivity, and safety. This study concluded that the chosen layoutfor the final layout showed a significant decrease in path length of material handling, i.e 45 meters or about 19,2%. Thedecreasing of material handling path length on the choosen layout was also influenced by the arrangement of the workplace by using 55 method.Key words: material handling, layout of plant facilities, Systematic layout planning, 5S Method

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.

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.

Loss and Flow Path Studies on Centrifugal Compressors—Part II

1970 ◽  
Vol 92 (3) ◽  
pp. 287-300 ◽  
Author(s):  
O. E. Balje´
Keyword(s):  
Boundary Layer ◽  
High Efficiency ◽  
Flow Path ◽  
Flow Conditions ◽  
Centrifugal Compressors ◽  
Mixed Flow ◽  
Path Design ◽  
Balanced Flow ◽  
Efficiency Data ◽  
Rotor Flow

The flow conditions in a mixed flow rotor are investigated for a “pressure balanced” flow path design. Boundary layer arguments are applied to calculate the losses in the rotor as well as in the subsequent diffuser section. The resulting efficiency data imply a comparatively high efficiency potential for mixed flow compressors with multiple cascaded components, designed on the premise of a “pressure balanced” rotor flow path.

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