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.

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.

Robot workstation failure recovery based on a layout optimization

2016 ◽  
Vol 40 (2) ◽  
pp. 375-388 ◽  
Author(s):  
Marko Filipović ◽  
Stjepan Bogdan ◽  
Tamara Petrović
Keyword(s):  
Objective Function ◽  
Flexible Manufacturing ◽  
Material Handling ◽  
Optimization Problems ◽  
Transportation Cost ◽  
Failure Recovery ◽  
Treatment Quality ◽  
Layout Problem ◽  
Material Handling Costs ◽  
Rate Of Failure

This article focuses on the robot workstation layout problem and briefly discusses a recovery control strategy. Since present industrial workstations utilize a flexible manufacturing cell served by a robot, researchers in this field try to find the best method determining the physical organization of resources in available space. As solving the facility layout problem (FLP) might reduce material handling expenses, the most common objective in these approaches is to minimize the material handling costs. Our work introduces a new approach in obtaining the optimal positions of resources in a robot workstation where considerable contribution to the final layout design comes from the failure recovery data. The optimization criteria include material flow and transportation cost as the standard FLP objectives. In our approach we also consider the resource rate of failure and treatment quality as a part of the failure recovery. The optimization problems were solved with the state of the art optimization algorithm for the nonlinear optimization problems. The computational results of the study are discussed and analysed on the basis of a real industrial application. The commonly used objective function is compared to the proposed objective function extended with the failure recovery. As an important part of the failure recovery strategy, making the proper recovery decision in the workstation control design is also discussed.

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.

A hybrid optimization approach for unequal-sized dynamic facility layout problems under fuzzy random demands

2019 ◽  
Vol 234 (3) ◽  
pp. 382-399 ◽  
Author(s):  
Shanshan Zha ◽  
Yu Guo ◽  
Shaohua Huang ◽  
Qi Wu ◽  
Pengzhou Tang
Keyword(s):  
Random Environment ◽  
Hybrid Algorithm ◽  
Material Handling ◽  
Simulated Annealing Algorithm ◽  
Facility Layout ◽  
Shop Floor ◽  
Optimization Approach ◽  
Hybrid Particle Swarm Optimization ◽  
Material Handling Costs ◽  
Fuzzy Random

Dynamic facility layout problems involve devising the optimal layout for each different production period. This article studies unequal-area dynamic facility layout problems under fuzzy random environment to minimize the sum of the material handling costs and rearrangement costs. For a more general situation, a novel model of unequal-area dynamic facility layout problems is proposed on the basis of fuzzy random theory, in which uncertain demands are characterized by fuzzy random variables. Unequal-area dynamic facility layout problems are one of the non-deterministic polynomial-time hard problems. Therefore, a hybrid particle swarm optimization and simulated annealing algorithm is innovated to solve the proposed unequal-area dynamic facility layout problems model under fuzzy random environment, in which the shapes and areas of facilities are changed dynamically. Two facility-swapping methods and two local search methods help hybrid algorithm escape from local optima, allowing a more reliable solution. Moreover, a new shifting method is developed to prevent the spatial overlapping between adjacent facilities and save material handling costs. The performance of the hybrid algorithm is confirmed by some test problems available. Finally, the proposed method is extended to a facility layout planning of a new aircraft assembly shop floor. Computational results show that the efficiency and effectiveness of the proposed method, in sharp comparison with other approaches.

scholarly journals Prayer paper production facility layout redesign using systematic layout planning method and CRAFT

2020 ◽  
Vol 1 (4) ◽  
pp. 448-456
Author(s):  
J Tampubolon ◽  
L D Agoestine Simangunsong ◽  
M D Agustina Sibuea ◽  
A C Sembiring and A Mardhatillah
Keyword(s):  
Material Handling ◽  
Manufacturing Industry ◽  
Raw Materials ◽  
Facility Layout ◽  
Layout Planning ◽  
Unit Distance ◽  
Paper Manufacturing ◽  
Systematic Layout Planning ◽  
Material Handling Costs ◽  
The Right

Abstract. The facility layout is a strategic design that is used for a long time. All manufacturing industries must pay attention to the right layout to increase the productivity of the industry. A prayer paper manufacturing industry located in the Tanjung Morawa area, Medan has an error in the placement of raw materials and the placement of production machines, so that the distance from the temporary warehouse to the printing and cutting work stations is far apart, causing high material handling costs. Seeing these problems, research was carried out to improve the layout of the facilities and redesign. The method used for this research is Systematic Layout Planning (SLP), which is one of the methods used to regulate a workplace in a factory by using two areas with high frequency and logical relationships with each other. And the Computerized Relative Allocation of Facilities Technique (CRAFT) Algorithm is a repair program, which is a program that looks for optimal design by making gradual improvements to the layout. CRAFT evaluates the layout by interchanging departmental locations. Inputs required for the CRAFT algorithm include initial layout, data flow or frequency of movement, cost data per unit distance, and the number of departments that do not change or remain. The CRAFT method is usually applied using Quantitative Systems (QS) software. By comparing the layout between SLP and CRAFT, the optimal result is obtained using the SLP method by reducing the distance between departments by 1.407 meters or a distance efficiency of 39.91%.

scholarly journals Evaluation of The Facility layout on The Fried Onion Production Process

2021 ◽  
Vol 328 ◽  
pp. 05008
Author(s):  
Rachmad Hidayat ◽  
Shofi fitrotis Salimah ◽  
Moh. Jufriyanto ◽  
M.Firman Khaqiqi
Keyword(s):  
Production Process ◽  
Material Handling ◽  
Facility Layout ◽  
Conventional Technique ◽  
Production Cycle ◽  
Production Flow ◽  
Production Lines ◽  
Long Time ◽  
Increase Productivity ◽  
Material Handling Costs

Analysis of the design of the facility layout can improve the performance of production lines such as decreasing congestion levels, minimizing material handling costs. PT. XYZ is one of the fried onion companies has constraints on the material handling system that is less efficient because it takes a long time in the process. Therefore, there will be improvements to the layout of PT. XYZ to increase productivity and shorten the time of the production cycle. The method used is From to Chart the method is a conventional technique commonly used for planning factory layouts and moving goods in a production process. From the results obtained that the proposed layout is better than the initial layout with a higher flow efficiency value of 86.18%. The proposed layout utilizes vacant land, so that the production flow does not repeat and does not rotate far, so that the distance between the areas is getting closer.

scholarly journals An Optimization Method for the Remanufacturing Dynamic Facility Layout Problem with Uncertainties

2015 ◽  
Vol 2015 ◽  
pp. 1-11 ◽  
Author(s):  
Lingling Li ◽  
Congbo Li ◽  
Huijie Ma ◽  
Ying Tang
Keyword(s):  
Material Handling ◽  
Facility Layout ◽  
Optimization Method ◽  
Layout Design ◽  
Lead Times ◽  
Facility Layout Design ◽  
Design For Remanufacturing ◽  
Stochastic Returns ◽  
Material Handling Costs ◽  
High Level

Remanufacturing is a practice of growing importance due to increasing environmental awareness and regulations. Facility layout design, as the cornerstone of effective facility planning, is concerned about resource localization for a well-coordinated workflow that leads to lower material handling costs and reduced lead times. However, due to stochastic returns of used products/components and their uncontrollable quality conditions, the remanufacturing process exhibits a high level of uncertainty challenging the facility layout design for remanufacturing. This paper undertakes this problem and presents an optimization method for remanufacturing dynamic facility layout with variable process capacities, unequal processing cells, and intercell material handling. A dynamic multirow layout model is presented for layout optimization and a modified simulated annealing heuristic is proposed toward the determination of optimal layout schemes. The approach is demonstrated through a machine tool remanufacturing system.

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