MATERIAL FLOW ANALYSIS AND PLANT LAY-OUT OPTIMIZATION OF A MANUFACTURING SYSTEM

The paper proposes the results of a research project developed by the authors in collaboration with a production system working in the field of manufacturing wood products. The first step of the project was an accurate analysis of the system and the design of new production documents in order to collect data about the system itself. The collected data have been used to propose an initial solution of plant lay-out. The second step of the project was the construction of a simulation model. The model has been used to find an optimal plant- layout configuration by means of genetic algorithms with the goal of material handling cost and shop order flow time minimization.

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

Jurnal Media Teknik dan Sistem Industri ◽

10.35194/jmtsi.v2i1.327 ◽

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)

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

Mathematics ◽

10.3390/math7020154 ◽

2019 ◽

Vol 7 (2) ◽

pp. 154 ◽

Cited By ~ 4

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.

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Carbon Accounting in Harvested Wood Products: Assessment Using Material Flow Analysis Resulting in Larger Pools Compared to the IPCC Default Method

Journal of Industrial Ecology ◽

10.1111/jiec.12538 ◽

2017 ◽

Vol 22 (1) ◽

pp. 121-131 ◽

Cited By ~ 13

Author(s):

Gediminas Jasinevičius ◽

Marcus Lindner ◽

Emil Cienciala ◽

Markku Tykkyläinen

Keyword(s):

Material Flow ◽

Flow Analysis ◽

Material Flow Analysis ◽

Wood Products ◽

Carbon Accounting ◽

Harvested Wood Products ◽

Ipcc Default

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PERANCANGAN FASILITAS PABRIK TAHU UNTUK MEMINIMALISASI MATERIAL HANDLING

Jurnal Teknik Industri ◽

10.22219/jtiumm.vol13.no2.133-141 ◽

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

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Protocol: Material flow risk evaluation for layout design

WPOM - Working Papers on Operations Management ◽

10.4995/wpom.v7i2.5710 ◽

2016 ◽

Vol 7 (2) ◽

pp. 43

Author(s):

Aída Sáez Más ◽

José P. García-Sabater

Keyword(s):

Material Flow ◽

Risk Evaluation ◽

Material Handling ◽

Flow Analysis ◽

Material Flow Analysis ◽

Layout Design ◽

Manufacturing Plants ◽

Reduce Risk ◽

Complexity Increase

<p><em>The need of design new layouts or redesign current situation to manufacture new products has increased principally due to changes in customer demand, on both variety aspects and quantity (Lu, Shpitalni, and Gadh, 1999). The complexity increase is also associated with the traffic generated by material handling equipment. This situation can be described as unsafe for workers. Many authors defend that during layout design/redesign a risk analysis is necessary. In contrast others believe that material flow analysis should be a mainly task during this step. Therefore, in this research both considerations have been integrated. So that it is proposed a protocol to evaluate the risk generated by material flow with handling equipment in manufacturing plants. This methodology identify the process steps and propose dimensions, measurables, tools and suggestions in order to analyse and reduce risk correctly. All the above aspects are validated in a case study of a complex assembly plant in the automotive sector.</em></p>

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Assessing the Effects of Accounting Methods for Carbon Storage in Harvested Wood Products on the National Carbon Budget of Lithuania

Forests ◽

10.3390/f9120737 ◽

2018 ◽

Vol 9 (12) ◽

pp. 737 ◽

Cited By ~ 2

Author(s):

Marius Aleinikovas ◽

Gediminas Jasinevičius ◽

Mindaugas Škėma ◽

Lina Beniušienė ◽

Benas Šilinskas ◽

...

Keyword(s):

Climate Change ◽

Material Flow ◽

Carbon Stock ◽

Flow Analysis ◽

Material Flow Analysis ◽

Wood Products ◽

Carbon Accounting ◽

Tier 2 ◽

Tier 3 ◽

Country Specific

Forests and the forest-based sector play important roles in mitigating climate change through carbon sequestration and storage in living biomass and soil. In Europe, the forest sector is the only sector that positively affects atmospheric carbon balance. After the forest harvest, a large share of carbon is removed together with the wood. This wood carbon might be stored for centuries if in the form of long-lived wood products. In 2011, the United Nations decided that countries should account for and report carbon balance not only in forests but also in harvested wood products (HWP), followed by very general guidelines on methods for carbon accounting in HWP. The Intergovernmental Panel on Climate Change (IPCC) proposed three methodological levels called tiers for estimating carbon stock and its changes in HWP. The first reporting period revealed that countries applied different carbon accounting methods (tiers), therefore comparing the carbon budgets of HWP and the effect of climate change mitigation among different countries is difficult. In order to test the differences between carbon accounting methods proposed by the IPCC guidelines, we applied two carbon accounting methods and used different data sources in the case of Lithuania. The methods applied were the IPCC Tier 2 method (data on HWP from statistics or the literature, default half-life values, and default HWP categories) and material flow analysis, which is compatible with the IPCC Tier 3 method (material flow data on HWP, country-specific half-life values, and country-specific HWP categories). Depending on the availability of historical data from different sources for the purpose of this study, three study periods were defined: 1992–2015 Food and Agriculture Organization Corporate Statistical Database (FAOSTAT) data, 1960–1991 data from the literature, and 1940–1991 data from national statistics. The study findings show that carbon stock in HWP significantly differed when different data sources and methods were applied. The highest carbon stock in HWP (19.5 Mt) at the end of the study period was observed when FAOSTAT data from 1992–2015 were used and the Tier 3 method was applied. The lowest carbon stock in HWP (11.2 Mt) at the end of the study period was observed when data from national statistics from 1940–1991 were used and the Tier 2 method was applied. The carbon inflow into the pool of HWP in all cases was estimated to be 40% higher when material flow analysis was applied compared to the IPCC default (Tier 2) method. These findings suggest that in general it is more reasonable to apply the Tier 3 method for carbon accounting of HWP in Lithuania.

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Life Cycle Assessment and Material Flow Analysis: Two Under-Utilized Tools for Informing E-Waste Management

Sustainability ◽

10.3390/su13147939 ◽

2021 ◽

Vol 13 (14) ◽

pp. 7939

Author(s):

Sohani Vihanga Withanage ◽

Komal Habib

Keyword(s):

Life Cycle Assessment ◽

Life Cycle ◽

Material Flow ◽

Keyword Search ◽

Technological Development ◽

Flow Analysis ◽

Material Flow Analysis ◽

Civil Society Organizations ◽

The Past ◽

Depth Analysis

The unprecedented technological development and economic growth over the past two decades has resulted in streams of rapidly growing electronic waste (e-waste) around the world. As the potential source of secondary raw materials including precious and critical materials, e-waste has recently gained significant attention across the board, ranging from governments and industry, to academia and civil society organizations. This paper aims to provide a comprehensive review of the last decade of e-waste literature followed by an in-depth analysis of the application of material flow analysis (MFA) and life cycle assessment (LCA), i.e., two less commonly used strategic tools to guide the relevant stakeholders in efficient management of e-waste. Through a keyword search on two main online search databases, Scopus and Web of Science, 1835 peer-reviewed publications were selected and subjected to a bibliographic network analysis to identify and visualize major research themes across the selected literature. The selected 1835 studies were classified into ten different categories based on research area, such as environmental and human health impacts, recycling and recovery technologies, associated social aspects, etc. With this selected literature in mind, the review process revealed the two least explored research areas over the past decade: MFA and LCA with 33 and 31 studies, respectively. A further in-depth analysis was conducted for these two areas regarding their application to various systems with numerous scopes and different stages of e-waste life cycle. The study provides a detailed discussion regarding their applicability, and highlights challenges and opportunities for further research.

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