Abstract: The purpose of this paper is to present the process of elaborating the layout of an assembly line of a welding industry using the principles of lean manufacturing as the main driver. The objective of this paper is relevant since the current layout of the assembly line causes non-productive times for operators, being related to the lean waste of unnecessary movements. The methodology used for the project development was Project-based Learning (PBL), which is an active way of learning focused on real problems. The process of selecting the methodology for layout planning was developed considering three criteria to evaluate the most relevant one for this paper's goal. As a result of this evaluation, Systematic Layout Planning was selected, and three steps were added to it – Value Stream Mapping for the current situation and after layout changed and the definition of lean tools and layout type. This inclusion was to consider lean manufacturing in the layout redesign of the industry. The layout change resulted in an increase in the value-adding time of operations carried out in the sector, reduction in movement times between previous and final assemblies, and in cost savings regarding the man-hour value of the employees, which can be invested in productive hours instead of movement times.
Abstract: Mass customization production increases the difficulty of the production line layout planning. The material distribution process for variety of parts is very complex, which greatly increases the cost of material handling and logistics. In response to this problem, this paper presents an approach of production line layout planning based on complexity measurement. Firstly, by analyzing the influencing factors of equipment layout, the complexity model of production line is established by using information entropy theory. Then, the cost of the part logistics is derived considering different variety of parts. Furthermore, the function of optimization including two objectives of the lowest cost, and the least configuration complexity is built. Finally, the validity of the function is verified in a case study. The results show that the proposed approach may find the layout scheme with the lowest logistics cost and the least complexity. Optimized production line layout planning can effectively improve production efficiency and equipment utilization with lowest cost and complexity.
Abstract: In this research, computer simulation is used for Electronic Manufacturing Service (EMS) plant layout analysis. The current layout of this manufacturing plant is a process layout, which is not suitable due to the nature of an EMS that has high-volume and high-variety environment. Moreover, quick response and high flexibility are also needed. Then, cellular manufacturing layout design was determined for the selected group of products. Systematic layout planning (SLP) was used to analyze and design the possible cellular layouts for the factory. The cellular layout was selected based on the main criteria of the plant. Computer simulation was used to analyze and compare the performance of the proposed cellular layout and the current layout. It found that the proposed cellular layout can generate better performances than the current layout. In this research, computer simulation is used for Electronic Manufacturing Service (EMS) plant layout analysis. The current layout of this manufacturing plant is a process layout, which is not suitable due to the nature of an EMS that has high-volume and high-variety environment. Moreover, quick response and high flexibility are also needed. Then, cellular manufacturing layout design was determined for the selected group of products. Systematic layout planning (SLP) was used to analyze and design the possible cellular layouts for the factory. The cellular layout was selected based on the main criteria of the plant. Computer simulation was used to analyze and compare the performance of the proposed cellular layout and the current layout. It found that the proposed cellular layout can generate better performances than the current layout.
Abstract: It is the living conditions in the cities that determine the future of our livelihood. “To change life, we must first change space"- Henri Lefebvre. Sustainable development is a utopian aspiration for South African cities (especially the case study of the Gauteng City Region), which are currently characterized by unplanned growth and increasing urban sprawl. While the reasons for poor environmental quality and living conditions are undoubtedly diverse and complex, having political, economical and social dimensions, it is argued that the prevailing approach to layout planning in South Africa is part of the problem. This article seeks a solution to the problem of sustainability, from a spatial planning perspective. The spatial planning tool, the urban development boundary, is introduced as the concept that will ensure empty talk being translated into a sustainable vision. The urban development boundary is a spatial planning tool that can be used and implemented to direct urban growth towards a more sustainable form. The urban development boundary aims to ensure planned urban areas, in contrast to the current unplanned areas characterized by urban sprawl and insufficient infrastructure. However, the success of the urban development boundary concept is subject to effective implementation measures, as well as adequate and efficient management. The concept of sustainable development can function as a driving force underlying societal change and transformation, but the interface between spatial planning and environmental management needs to be established (as this is the core aspects underlying sustainable development), and authorities needs to understand and implement this interface consecutively. This interface can, however, realize in terms of the objectives of the planning tool – the urban development boundary. The case study, the Gauteng City Region, is depicted as a site of economic growth and innovation, but there is a lack of good urban and regional governance, impacting on the design (layout) and function of urban areas and land use, as current authorities make uninformed decisions in terms of development applications, leading to unsustainable urban forms and unsustainable nodes. Place and space concepts are thus critical matters applicable to planning of the Gauteng City Region. The urban development boundary are thus explored as a planning tool to guide decision-making, and create a sustainable urban form, leading to better environmental and living conditions, and continuous sustainability.
Abstract: This paper presents an algorithm which
combining ant colony optimization in the dynamic
programming for solving a dynamic facility layout problem.
The problem is separated into 2 phases, static and dynamic
phase. In static phase, ant colony optimization is used to find
the best ranked of layouts for each period. Then the dynamic
programming (DP) procedure is performed in the dynamic
phase to evaluate the layout set during multi-period planning
horizon. The proposed algorithm is tested over many
problems with size ranging from 9 to 49 departments, 2 and 4
periods. The experimental results show that the proposed
method is an alternative way for the plant layout designer to
determine the layouts during multi-period planning horizon.
Abstract: The objective of this research is to study plant layout
of iron manufacturing based on the systematic layout planning
pattern theory (SLP) for increased productivity. In this case study,
amount of equipments and tools in iron production are studied. The
detailed study of the plant layout such as operation process chart,
flow of material and activity relationship chart has been investigated.
The new plant layout has been designed and compared with the
present plant layout. The SLP method showed that new plant layout
significantly decrease the distance of material flow from billet
cutting process until keeping in ware house.