Development of Plant Layout Using Systematic Layout Planning (SLP)

Proceedings of 07th IRF International Conference, 22nd June -2014, Bengaluru , India, ISBN: 978 -93-84209 -29-2 124 DEVELOPMENT OF PLANT LAYOUT USING SYSTEMATIC LAYOUT PLANNING (SLP) TO MAXIMIZE PRODUCTION – A CASE STUDY 1ORVILLE SUTARI , 2 SATHISH RAO U 1M.Tech.(Mfg. Engg.), M....

Proceedings of 07th IRF International Conference, 22nd June -2014, Bengaluru , India, ISBN: 978 -93-84209 -29-2 124 DEVELOPMENT OF PLANT LAYOUT USING SYSTEMATIC LAYOUT PLANNING (SLP) TO MAXIMIZE PRODUCTION – A CASE STUDY 1ORVILLE SUTARI , 2 SATHISH RAO U 1M.Tech.(Mfg. Engg.), M.I.T, Manipal, 2Asst. Professor (Dept. of Mech. and Mfg. Engg.), M.I.T, Manipal, Abstract -The objective of this research is to study the existing plant layout of a nacelle production unit and to design a lean plant layout using SLP (Systematic Layout Planning) to increase its productivity . Analysis of the existing plant layout was made by studying aspects like flow of materials, activity relat ionships and space requirements. New plant layout alternatives were design ed and compared to the existing layout. The new plant layout finally selected s how ed a significant decrease in the distance of material and work flow travel and resulted in increasing the productivity of the unit . Index Terms - Activity Relationship Chart, Facility layout, Lean , Systematic Layout Planning I. INTRODUCTION Plan t layout refers to the arrangement of physical facilities such as machinery, equipment, furniture etc. with in the factory building in such a manner so as to have quickest flow of material at the lowest cost and with the least amount of handling in processi ng the product from the receipt of material to the shipment of the finished product. Plant layout opt imization is a crucial step towards making an industry more lean. It helps to eliminate non -value adding work caused due to poor layout design and manageme nt. The manufacturing throughput time is also great ly reduced, therefore decreasing productivity and increasing cost s. Previous case studies have shown the practical significance of using SLP in improving productivity and utilization of spa ce in a producti on unit . Manufacturing industries are always under pressure from t heir shareholders to improve productivity. They are not only being compared with their competitors, but also within their own group of companies. An organization can therefore not just look at the competition on their local market, but it has to compare itself with factories all over the world. This case study was carried out at a nacelle production unit having a process type layout. The problems faced by the unit are more time and cost of manufacturing as a result of an inefficient plant layout . It is seen that the distances travelled by components and personnel during the man ufacturing process is a cause for delays in manufacturing. Excess movement and transport is also a cause for extra costs and wasted energy. With these problems in mind, the SLP technique is applied to Fig. 1. Procedure of SLP Optimize the existing layout and reduce the wastes. The basic analysis of the existing layout is done by establishing the relationships of th e different activities in the layout. Space required for each activity area and the necessary equipment is determined. After analyzing the existing layout, a new layout is designed . A final layout plan is selected after making necessary adjustments and eva luation s in a ccordance with any practical limitations . The SLP techni que gives a good result in improving work flow during the manufacturing process. Fig. 2. Process Flow Chart Development of Plant Layout Using Systematic Layout Planning (SLP) To Maximize Production – A Case Study Proceedings of 07th IRF International Conference, 22nd June -2014, Bengaluru , India, ISBN: 978 -93-84209 -29-2 125 II. BASIC OUTLINE OF LAYOUT DEVELOPMENT The tasks carried out in the SLP method used broadly falls into two phases; analysis and design. Fig. 1. shows the general procedure of SLP in the form of a block diagram. Fig. 3. Activity Relationship Chart III. ANALYSIS OF THE EXISTING PLANT LAYOUT This step in SLP deals with the gathering of all the information and data that is required to facilitate the design of an optimized plant layout. There are two types of products being manufactured namely, nacelle and nose cone. The nacelle and nose cone are produced in the same quantities and are de livered as a set. Table I Distances travelled in the existing layout Fig. 4(a). Dimensionless Block Diagram of Layout 1 Fig. 4(b). Dimensionless Block Diagram of Layout 2 A. Flow of Materials The analysis is done on the flow of materials for the two p roducts being manufactured. The sequence of operations performed in the manufacturing process forms the basis for the analysis of flow. Fig. 2. shows the process chart which is applicable to both nacelle and nose cone since the steps in their processes are largely the same. Table II Relationship between equipment size and work area Development of Plant Layout Using Systematic Layout Planning (SLP) To Maximize Production – A Case Study Proceedings of 07th IRF International Conference, 22nd June -2014, Bengaluru , India, ISBN: 978 -93-84209 -29-2 126 Fig. 5 (a). Plant Layout : Original Fig. 5 (b). Plant Layout : Proposed Layout 1 Fig. 5 (c). Plant Layout : Proposed Layout 2 B. Motion and Transportation The term motion is u sed for the movement of people, and transportation for the movement of objects. Quantitative data was obtained to calculate the total distances travelled in terms of motion and transportation during the manufacturing process. Table I displays the data for both th e nacelle and nose cone for the existing plant layout. It presents the from -to distances between different locations for each major process in their manufacturing. The data serves as a baseline and is useful in determining the degree of closeness n ecessary between different departments for material interaction. Efforts are made in layout design to place the departments having more material movement close to each other to minimize material handling. It was seen that movement of raw materials was carried out over long distances. Also, the flow of work was not optimum due to disjoined depa rtment areas . C. Activity Relationship Chart An activity relationship chart (ARC) is one that displays the closeness rating among all pairs of activities or departm ents. In an ARC there are six closeness ratings which may be assigned to each pair of departments. They are defined as A: Absolutely necessary, E: Especially important, I: Important, O: Ordinary, U: Unimportant and X: Undesirable. To make the chart we we re required to consider qualitative aspects like flow of material, ease of super vis ion and unsafe conditions. This was discussed with the work team leaders and supervisors to help identify the relative importance of having one department near to other. The relationship chart as shown in Fig. 3. was prepared after considering both quantitative data of distances travelled as well as the qualitative data collected from working personnel. D. Space Requirements It is important to also consider the space requi rements of each department area in relation with the work equipments. The equipment type and the space they occupy is listed alongside their respective departments in Table II. This data helped in the design phase of the layout planning when relocating the departments. IV. DESIGN OF NEW AND ALTERNATE PLANT LAYOUTS The data collected from the analysis phase of the layout planning was used in proposing new and alternate plant layouts which were checked for optimum flow of work through the processes. A. Dimension less Block Diagram The dimensionless block diagram s in Fig. 4. are prepared based on the relationship chart and serves as a basis for two new alternate layout s. The departments are numbered in the same manner as seen in the ARC. The block diagram ignores s pace and building constraints, and gives us a better idea for designing the optimized layout. B. Proposed Layout The SLP techniqu e resulted in two new alternat e plant layouts after taking into consideration any practical limitations and constraints. Fig. 5. shows the original layout as well as proposed layout s 1 and 2 , drawn to scale. E ach square in the figure grid represent s an area of 6.25 m 2. Table III Distances travelled in the optimized layout Development of Plant Layout Using Systematic Layout Planning (SLP) To Maximize Production – A Case Study Proceedings of 07th IRF International Conference, 22nd June -2014, Bengaluru , India, ISBN: 978 -93-84209 -29-2 127 V. RESULTS OF THE LAYOUT DEVELOPMENT The proposed layout 1 was finally selected as the new optimized plant layout. With the new layout all dis joined department areas were made as one and efficient material flow was achieved. Table III shows the total overall distances travelled in the optimized layout plan. The total distance travelled for nacelle is reduced by 292 m and for nose cone by 47.05 m. There fore in the optimized layout, the total distance reduced in the manufacturing of one set of nacelle and nose cone is 339.05 m. By the application of SLP for the des ign of an optimized plant layout we were able to reduce the wastes due motion and transportation , therefore in creasing the productivity of the plant. REFERENCES [1] Chandra Shekhar Tak , Lalit Yadav , “Improvement in Layout Design using SLP of a small size m anufacturing unit: A case study ,” IOSR Journal of Engineering , vol. 2, pp. 01 -07, October 2012 [2] Subodh B. Patil , S. S. Kuber, “Productivity Improvement in Plant using Systematic Layout Planning (SLP) – a Case Study of Medium Scale Industry ,” International Journal of Research in Engineering and Technology , vol. 3, pp. 770 -775 , April 2014 [3] Pramod P. Shewale , Manmath S. Shete , S. M. Sane , “Improvement in Plant Layout using Systematic Layout Planning (SLP) for Increased Productivity , ”International Journal of A dvanced Engineering Research and Studies , vol. 1, pp. 259 -261 , April -June 2012 [4] M. Khansuwan, C. Poowarat, “A Study on Plant Layout Improvement: a Case Study at Kritchai Mechanical Company Ltd. ”, a project for Bachelor’s degree in Industrial Engineering, Faculty of Engineering Thammasat University, 1999 [5] Vinod Arya, Sanjeev Singh Chauhan, “ Increased Productivity and Planning by Improved Plant Layout using Systematic Layout Planning at NCRM Division, Bhushan Steels Ltd. 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