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Application of Simulation Technique for Improving Plant Layout in Ceramic Factory

Kasemset Chompoonoot, Opassuwan Takron, Tangsittikhun Thanakit, Chaiyajina Nititada

Production Engineering Archives

2023

Vol. 29, Iss. 2

186-194

This study aims to design and improve the plant layout of a ceramic factory by adopting Systematic Layout Planning (SLP) and the simulation technique. A ceramic company in northern Thailand is selected as a case study. Three ceramic products including roof tiles, wall tiles and dishware are studied due to their highest production volume. Through the SLP approach, information regarding the number of departments and machines, the area of the plant, the frequency of movement and the distance between each department is collected for the analysis of the relationship between departments. Two plant layout designs are then proposed; the first one is derived from the Computerized Relationship Layout Planning algorithm (CORELAP), and the second one is the process layout. For selecting the most appropriate layout design, five criteria are considered including total distance, the average total process time of each unit produced, ease of movement, material flow and safety. To determine the distance and the average total process time per unit, Distance-Based Scoring and simulation techniques are conducted while the ease of movement, material flow and safety are rated based on whether the company satisfies each criterion. Employing the weight scoring technique, the results report that the CORELAP layout is the most suitable for further implementation due to its highest weighted score equal to 2.536 while the process layout receives 2.386. Implementing the CORELAP layout can reduce the total distance by 16.76% while the average total process time per unit of the CORELAP layout is not significantly different at the significance level of 0.05 as compared to the existing layout.

Model based enterprise manufacturing capacity definition and product cost estimation for SME

Sahno J., Polyantchikov I., Pribytkova M., Shevtshenko E.

Journal of Machine Engineering

2011

Vol. 11, No. 1-2

23--34

In today's business environment enterprises are trying to establish reorganization changes in their work and organization. It is necessary to structure the existing business to understand all enterprise functions, and change them in order to achieve the main enterprise objectives. To stay competitive under new conditions the external and internal factors should be assessed before restructuring of existing practices. The goal of this paper is to show how to put into practice the process of transition from Small-sized enterprise to Medium-sized enterprise category. For this purpose the existing company data that is stored in the ERP system should be transformed into knowledge. In this paper we consider the conditional "Metal Service" enterprise that produces various metal constructions and plans to produce load lifting equipment (jib cranes, overhead cranes, and additional equipment for existing cranes) for manufacturing enterprises that produce heavy products. The manufacturing capacities of enterprise are defined based on IDEF0 functional model created for each type of product. The simulation results received from these models enables to analyse new production processes, to estimate production time and route for all type of unit and yearly product release. In addition, after the Systematic Layout Planning (SLP) methodology and Relationship Matrix (RM) was applied to simulation results it became possible to calculate new manufacturing area, facilities layout and to assess the new production capacities.