IE03 Review on various methods for designing a new ...

Proceedings of 2nd International Conference on Emerging Trends in Mechanical Engineering, February 24th - 25th, 2017 G H Patel College of Engineering & Technology, V V Nagar - 388120, Gujarat, India ISBN: 978-93-84659-77-6

IE03 Review on various methods for designing a new facility of assembly line Vichesha Yardi1∗, Prof. Vivek A Deshpande2 1Post

Graduate student, 2Assistant professor, Mechanical Engineering Department, G. H. Patel College of Engineering & Technology, V.V.Nagar-388120, Gujarat, India. (Corresponding Author: [email protected])

1, 2

Abstract It is important for any organization to give attention to the facility layout design to achieve effectiveness and efficiency which will lead them to delight the customers. The facility layout design is a concept which utilizes all the resources in effective way with available floor space to optimize smooth running of operations by considering safety and convenience of the employees. This paper deals with the various methods which are applied to design a new facility layout of an assembly line. It is a comparative study of different types of methodologies implemented for designing and balancing an assembly line. The importance of all techniques to apply on specific problems and the selection of an appropriate approach for identified problem is discussed further. . Key words: assembly line design, facility layout planning 1.

Introduction

1.1

Facility Layout Design Concept

Facility layout design is systematic concept of utilizing all available resources in an optimum manner to achieve maximum utilization of the capacity. The need of optimizing a new layout design or redesign is to match with the fast change in customer demand in both the product quantity and variety by improving and increasing utilization of machine, labor and space, improving production line performance such as decrease bottleneck rate, decrease material handling cost and reducing ideal time [1]. There are different techniques to obtain facility layout design like Systematic Layout Planning (SLP), Quadratic Assignment Problems (QAP) for discrete representation, Mixed Integer Programming (MIP) for continual representation, Fuzzy linear programming if using fuzzy data and modularization. Other approaches aided by computer programming such as CRAFT (Computerized Relative Allocation of Facilities Technique), CORELAP (Computerized Relationship Layout Planning) and ALDEP (Automated Layout Design Program) [2]. Some resolution approaches also known as heuristic/metaheuristic such as Genetic Algorithm, intelligence search algorithm and particle swarm optimization. Many case studies have explained application of different heuristic approaches to solve QAP which is an NP-hard problem introduced by Koopmans and Beckman [3]. Some important factors should be considered while designing a facility layout. For example, material handing cost, which has a big contribution toward operation handling cost up to 50 to 60 percent of product cost and take 50 percent of production time. There are safety and ergonomic issues

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too which become constraints for any 2 facilities to be closed even though their material handling cost is high [4]. 1.2 Assembly Line Design Facility design for the manufacturing Assembly Line was first introduced by Henry Ford in the early 1900’s [5]. An assembly line typically consists of a number of workstations arranged in sequence and linked by a conveyor. The workstations can either be automated performed by robots or manual where the operator carries out work or even semi-automated where an operation is carried out by human and machine both [6]. Further classification of an assembly line is as 1) single model line, to carry out single product, 2) mixed model line, to produce similar models of a product 3) multi model line, to produce various similar or different models in large batches [7]. There are four fundamental principles like Division of labor, workflow, the principle of interchangeability and minimum distance moved which are considered as a basis for most assembly system. The assembly line is a combined process of two subsystems; the material handling subsystem which is designed based on the principle of work flow and minimum distance move and the operation line subsystem designed with the principle of division of labor and interchangeability of parts [8]. 2.

Specific Domain

Literature study of the review paper is focused on facility layout design which is narrowed down by specifying a layout of an automotive industry. Furthermore the various approaches to facilitate activities of a combination layout of an assembly line are preferred and discussed further. 3.

Literature review

Systematic Layout Planning is a technique established by Richard Muther, is a step by step planning procedure allowing users to analyze different activities, their relationship with each other and alternatives involved in a layout design project. The main areas of SLP method are Activity relationship, space required to those activities and adjustment. Each has further sub contents of the collection of input data such as flow of materials, activity relationship diagram, required space and available space, space relationship diagram, modifying considerations, practical limitations, evaluation and final selection [9]. Maynard Operation Sequence Technique (MOST) developed by H. B. Maynard, Kjell Zandin and company in 1974 [10]. It is an Industrial Engineering technique used for work measurement which allows better productivity and resource optimization. This is achieved by dividing total work into no. of elements and evaluating individual element to remove non-value added activities to make the smooth running of the process and cost saving. This tool can also be used for the smooth running of assembly line facilities. The concept is applied to an assembly line of wiring cable to achieve the same as mentioned. After implementing the MOST technique, the results show the savings of 13 lacs per annum approx. DCOV (Design, Characterized, Optimize and Verify) a roadmap of Design for Six Sigma (DFSS) along with simulation has achieved the implementation of buffer configuration [6]. Whereas SLP with Lean concept provides a solution by eliminating the 7 types of waste (MUDA) defined by Toyota’s Chief engineer [11]. For eliminating 7 wastes and to identify current state of company, the value stream mapping is conducted which will result in generating alternatives of facility design and for designing a future state map of a company based on changes.

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Modularity is a general concept developed for designing an assembly line for some parts of product which involves layout design, buffer design, line balancing, transportation design and resource selection which leads to modularization of product architecture, production and interfirm system [12]. This concept is applied at the workstation identified as a bottleneck. The total parts assembled at the workstation are divided into simple modules and as a result, the general components are assembled separately to reduce assembling time. Bowl shape configuration can be achieved by positioning bottleneck workstations at the end of assembly line and fast moving workstation at the centre, also known as imbalanced assembly line technique [13]. Simulation concept is used to model a dice game same as in TOC. Simulation is applicable where the system behavior hypothesis has to match with reality. This method suggests the help on a trade-off; cost reduction with less WIP and better throughput versus cost of investment in new assets. Improvement in balancing losses and efficiency by reducing material handling and transportation cost was achieved by using the fuzzy concept and Multi Objective MIP [5, 14]. Application of heuristic/meta-heuristic method and intelligence approaches known as the resolution approach is used to solve facility layout problem [2]. One of the techniques is used to solve QAP is Sule’s method and Genetic Algorithm for industry application to reduce the total cost to move material between facilities [15]. Non-dominated sorting genetic algorithm (NSGAII) and multi-objective particle swarm optimization (MOPSO) together as a new mathematical model is presented considering balancing a mixed-model U-line and human-related issues [16]. The first section is related to balance problem with objective functions as minimizing the cycle time, minimizing workstations and maximizing the line efficiencies whereas the another section is related to the human issues with objective functions of hiring-firing cost, training cost and salary. Human resource planning effects should be considered as these activities are not deterministic. Another method to design assembly line facility is Intelligence Search Algorithm for which the input data is the information about product, process and resource [17]. This methodology is followed in two stages: analytical calculation to determine no. of resources per process, no. of resources per station and no. of operations per resources whereas in stage two, the previous design is detailed by use of an intelligent algorithm to select specific resource for each station. CRAFT method requires flow matrix, distance matrix and cost matrix as input data along with initial layout in the program [3]. Redesign of the present layout using CRAFT method is considered to reduce transportation cost between workstations, production time reduction and distance moved by product within the facility [1]. By using CORELAP method the proposed layout has material handling distances that are shortened by 9.017% compared with the current layout [18]. The proposed layout by ALDEP technique indicates the savings in material handling cost by 23% i.e. Rs. 44.75 Lacs per annum along with other benefits like increased productivity, less worker efforts [19]. Table 1 Summery of methods mentioned in this paper Method Quadratic assignment problem Systematic layout planning CRAFT CORELAP

Founder Koopmans and Beckmann Richard Muther Armour and Buffa R C Lee and James Moore

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Year 1957 1961 1963 1967


ALDEP Intelligence search algorithm Genetic algorithm Bowl shape configuration (TOC) DFSS Particle swarm optimization Mixed Integer Programming

Seehof and Evans Peter Hart, Nils Nilsson and Bertram Raphael John Henry Holland Eliyahu M. Goldratt Bill Smith at Motorola James Kennedy Meller

1967 1968 1970 1984 1986 1995 1998

Table 1 describes the various methods discussed here for optimizing a facility layout sorted out by year. 4.

Review remark

As it can be observed that the awareness of how the design of layout has a tremendous effect on efficiency and productiveness of any manufacturing plant is spread among industrialists which geared up revolutionary improvements in design techniques during the late 20th century. It is difficult to design an assembly line maintaining a tradeoff between minimum cost and facility. Systematic layout planning is most old technique yet used in recent which provides sequential guidelines to user. Methodologies like Systematic layout planning, DCOV with simulation and Intelligence Search Algorithm are applied to design new facility whereas remaining techniques are applied on existing facility layout. 5.

References

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