Layout Designing Using Systematic Layout Planning For Electronics .
International Journal of Current Engineering and Technology 2017 INPRESSCO , All Rights ReservedE-ISSN 2277 – 4106, P-ISSN 2347 – 5161Available at http://inpressco.com/category/ijcetResearch ArticleLayout designing using Systematic Layout Planning for ElectronicsDivision of a Manufacturing FacilityVarsha Karandikar*, Shriram Sane, Darshan Rathod , Aakash Jaiswal and Shubham VisputeDepartment of Industrial & Production Engineering, Vishwakarma Institute of Technology, Savitribai Phule Pune University, Pune, IndiaReceived 15 Aug 2017, Accepted 05 Oct 2017, Available online 11 Oct 2017, Vol.7, No.5 (Sept/Oct 2017)AbstractAt a manufacturing facility, the management decided to merge all the electronic product divisions spread over threebranches into one location. The main objective of the paper was to systematically arrange all the sub divisions inaccordance with the parent divisions. This was achieved by implementing the systematic layout planning (SLP) tool.The paper at hand focuses mainly on products, product families, tools, material handling equipment, utilities anddifferent processes and the placement of the various departments based on their interdependency. Also, a detailedstudy of the plant layout using operation process chart, material flow chart and activity relationship chart wascarried out.Keywords: Systematic Layout Planning (SLP), ALDEP, CORELAP, Activity Relationship Chart1. Introduction1 Facilityplanning is an overall approach concernedwith the design, layout and incorporation of people,machines and activities of a system. Huang emphasizesthat facility layout design defines how to organize,locate, and distribute the equipment and supportactivities in a manufacturing facility to accomplishminimization of overall production time, maximizationof operational efficiency, growth of revenue andmaximization of factory output in conformance withproduction and strategic goals.The systematic layout planning (SLP) is a tool usedto arrange a workplace in a plant by locating areaswith high frequency and logical relationships close toeach other. The process permits the quickest materialflow in processing the product at the lowest cost andleast amount of handling. Muther has proposed thismethodology to design plant layout based on analysis,search and selection procedure. In this paper twoalternate layouts were prepared using AutomatedLayout Design Program (ALDEP) and ComputerizedRelationship Layout Planning (CORELAP). ALDEP isconstruction based algorithm and is used whenactivity relationship is a major consideration. Itdevelops a layout design by randomly selecting adepartment and placing in the layout. Thedepartments are placed in layout based on itscloseness rating. CORELAP is also a constructionalgorithm with activity relationship a majorconsideration. It is designed to accommodate*Corresponding author’s ORCID ID: 0000-0002-7847-6928situations when constantly changing conditionsprohibit the collection of precise numerical data. (CheeAiling et al)Company X is a leader in process efficiency andenergy conservation for Process Industry, with overseven decades of experience building steamengineering and control instrumentation solutions. Atthe Company’s new facility there was unreasonablematerial handling and excessive transportation whichlead to problems in material flow and hence resulted inless production than available capacity. Due tocontinuous expansion in the electronic segment and toexercise close control on the production lines, themanagement decided to redesign the layout for theelectronic division. This paper aims to design a newlayout using Industrial Engineering tools to satisfy themanagement’s requirements.2. Objectives of the ResearchTo arrange the product lines in a systematic manner soas to exercise close control for efficient management.To facilitate extension or change in the layout toaccommodate new product line and technologyupgradation. To organize the product lines in order to establisha streamline material flow.To reduce movement of workers, raw material andequipmentTo utilize the available space in an optimalmanner.1878 International Journal of Current Engineering and Technology, Vol.7, No.5 (Sept/Oct 2017)
Varsha Karandikar et al Layout designing using Systematic Layout Planning for Electronics Division of a Manufacturing FacilityTo ensure that the new layout satisfies theessential safety requirements and create safe andcomfortable work environment.Figure 2 Product ClassificationSupporting Service (S)- The team identified that forcertain products, additional utilities were required.These utilities supported the production of theproducts and were identified as follows:Figure 1 Systematic Layout Planninga.b.c.d.e.Water lineAir lineUsage of CraneAir conditioningWork-In-Process Inventory area3. Methodology3.2.After the team was assigned the task of developing anew layout for the Electronics Division at the facility, itwas decided that the most appropriate tool forachieving the desired objective would be SystematicLayout Planning (SLP) methodology. And as per themethodology the first step was to gather Input Dataand Activities.In order to identify the material flow it was necessaryto chart the flow process of raw material from RawMaterial Stores (RMS) to the production line and thesubsequent dispatch of finished products to theFinished Goods Store (FGS). The Flow Process ChartMaterial Type (FPC) enabled researchers to classifyeach activity performed into3.1.Input Data and ActivitiesThe first step was to gather data about the currentsetup and information about the various sub divisionsinvolved. This information was related to the productsand the product families existing within the facility.The variables configured by the team were:Product (P)- P is defined as the products which arebeing manufactured within the division. Theseproducts were systematically categorized under thefollowing categories as established by theManagement.1)2)3)4)1)2)3)4)5)Flow of MaterialsOperationInspectionTransportationMaterial WaitingStorageThe FPC for DCEM assembly is shown in the Figure .Similarly, FPC for the rest of the products was chartedwhich helped in determining the most effectivesequence of work and material.Analytical DivisionBoiler House DivisionCodel DivisionIntegrated Systems DivisionRouting (R)- In order to determine the path throughwhich the various products travel, it was required todesign the blueprint of the original layout usingAutoCad. This blue print enabled researchers to gaininsights of the present working conditions of theexisting facility and the need for devising a new layoutthat would optimize the material flow.Figure 3 Material Flow Process Chart- DCEM Assembly1879 International Journal of Current Engineering and Technology, Vol.7, No.5 (Sept/Oct 2017)
Varsha Karandikar et al3.3.Layout designing using Systematic Layout Planning for Electronics Division of a Manufacturing FacilityActivity Relationship ChartIn this stage, the identification of the relationshipsbetween different product lines is discussed. Theproduct lines are the various sub divisions of theelectronic division. The relationships were tabulated inan activity relationship chart. The team identified thevarious factors which defined interdepartmentalrelationships. These factors includedA.B.C.D.Intra- departmental material and information flowInter- departmental material and information flowMaterial Handling Equipment RequirementUtilitiesIn order to decide the ranking of the relationship thateach department shares with the others, theconventional ranking system was used which is asfollows.Figure 7: Relationship Diagram3.5.Figure 4: REL Chart Precedence RatingSpace Requirements and AnalysisAfter defining the relationships among processes, thenext step is determining the space requirementsneeded for each process to translate it into the actuallayout. The space requirements discussed and ments utilize space on the shop floor as follows:Table 1 Area Requirement - AC regionTypeFigure 5 Activity Relationship Chart3.4.Relationship DiagramThe activity relationship diagram is a visualdisplay of the activity relationship chart. Differentcolored lines are used to distinguish theimportance between each process as shown in theFigure.Figure 6 Relationship Diagram M ASSEMBLYCODEL OFFICEGCEM CALIBRATION LABDCEMSHINKAWASHINKAWA OFFICESHINKAWA STORAGESYSTEMSDCSDCS STORAGEDCS OFFICEDCS CUSTOMERE TO PSMART PRO CALIBRATIONSMART PRO ASSEMBLYVIBTRANSSMART POSITIONERBHDTotal AC AreaGangwayExisting2)Area (m441663662553256244025621108729Table 2 Area Requirement - Non AC regionTypeDeptNon ACNon ACNon ACNon ACCodelISAnalyticalABC 2FUNCTIONGCEM WELDIS WIPAnalytical Panel AssemblyABC 2 WIPTotal Non-AC AreaGangwayExisting2Area (m )366845308457445902In addition to these departments new departmentswere to be added which had to be accommodated in1880 International Journal of Current Engineering and Technology, Vol.7, No.5 (Sept/Oct 2017)
Varsha Karandikar et alLayout designing using Systematic Layout Planning for Electronics Division of a Manufacturing Facilitythe modifying layout. Also, due consideration had tobe given to modify the existing layout in order tosimplify the flow of the materials.3.6.Space Available It was required to be placed by considering theinstallation difficulties of existing crane facilities.Additional area was required for free materialflow.3.7.4. GCEM AssemblyThe total space which was has been decided by themanagement for supporting the new layout includesthe current layout area as well as additional area asbelow. Area was to be expanded to accumulate sufficientWIP inventory and their respective fixtures andfor enhancing accessibility of monitoring systemswith the product.Table 3 Area Requirement of Newly added sectionsTypeDeptNon AC CodelNon- ACNon-AC CommonNon-ACFUNCTIONCSD LabRMSFGSFree SpaceArea(m2 )5821843640411163.7.5. New Rig Area 3.7.6. Codel OfficeThe total area available for modification purposeconsisted of the existing area covered by the layoutand the additional area considered by themanagement which summed up to 2748 m2. 3.7. Modifying Constraints and Practical LimitationsThe primary considerations while developing the newlayouts were as follows: Workstations and departments should be placedby considering the internal as well as externalmaterial flow.All departments should be placed in accordance totheir parent divisions.Central gangway provided which will enhanceaccessibilityIS Division and GCEM Assembly section placed oneither side of the gangway for optimized use ofboth the cranesAfter learning about the space requirements and thespace available, the team identified certain constraintsand limitations. These points have been systematicallydocumented as follows:3.7.1. CSD Lab For rework of Codel related products aseparate section was to be provided (Aftersales service)The position of the lab was not to be changedas it would had been a costly affairdismantling the rigs and piping system. It was required to be placed outside the AC regionfor proper ventilation of welding fumes.It was to be placed in isolation due to its excessivenoise.It was to be placed such that the exhaust systemdoesn’t affect the aesthetics of the outer side ofthe building3.7.8. Analytical WIP It was to be placed outside the AC region becauseit didn’t require air conditioning.Sufficient area was to be allotted to accumulate alltypes of inventories.3.7.9. PCB Test Cell It was to be accommodated inside the AC regionbecause the PCB required dust free environment.It was to be placed in accordance to relation withPCB requiring departments.3.7.10. Smart Positioner 3.7.3. GCEM Weld Centrally located office was to be established withrespect to all Codel departments3.7.7. Thermal Cycle Chamber3.7.2. Calibration Lab Separate area was to be allocated for customertesting of ready-to-dispatch products Area was to be expanded to satisfy all present andfuture requirementsHall Sensor Assembly and PCB Assemblyworkstations were to be included near theassembly line.Racks were to be added to accumulate differenttypes of inventoriesSeparate workstations were to be provided forassembly of housing, PCB and hall sensor(Previously done on top of wooden WIP rack)Extra space was to considered for oncoming newfixtures.1881 International Journal of Current Engineering and Technology, Vol.7, No.5 (Sept/Oct 2017)
Varsha Karandikar et alLayout designing using Systematic Layout Planning for Electronics Division of a Manufacturing Facility3.7.11. Vibtrans – (Product name) Area was to be expanded for oncoming newproduct (Vibtrans Rack) 3.7.12. Smart Pro It was to be placed in accordance to Hydro TestRig which was not to be disturbed.Dedicated workstations were to be provided foreach processRacks were to be added to accumulate differenttypes of inventoriesUnnecessary tables were to be (currently used forstoring WIP) removed3.7.13. E/P 3.7.14. Analytical Panel Assembly Separate WIP area was to be added in the layoutto optimize assembly area.Meeting room for BHD and IS division relateddiscussion was to be established.3.7.16. IS WIP 3.8.Dedicated space for storage of IS WIP was to eprovided.Develop Alternate LayoutsInitial designs were created using the requirementsand constraints described before. This was done usingtwo Layout construction algorithmsA. Automated Layout Design ProgramB. Computerized Relationship Layout PlanningALDEP is basically a construction algorithm but it canalso be used to evaluate two layouts. The algorithmuses basic data on facilities and builds a layout bysuccessively placing the layout using relationshipinformation between the departments. The basicinputs to ALDEP are: The input data of CORELAP are 3.7.15. Customer Meeting Room CORELAP constructs layouts by locating rectangularshaped departments when the departmental area andlayout scale permit a rectangular representation of thedepartmental area. It is based on REL chart andnumerical weighted rating assigned to the closenessratings. The evaluation phase employs a placing ratingand a boundary length. Dedicate department was to be established forE/P productLength and width of facility. Length 75m Width 15mMinimum closeness preference (MCP) value. MCP value is 4Sweep width. Value is 3Relationship chart showing the closeness rating. Refer the relationship chart in FigureLocation and size of any restricted area. Number of departments No. of departments are 23Relationship chart Refer the relationship chart in FigureWeights for relationship chartDepartment pre-assignment (only along theperiphery of the layout.)GCEM calibration lab is assumed to be preassignedTable 4 Departmental AreasDEPTFUNCTIONAREA1GCEM WELD38.22GCEM ASSEMBLY45.63CODEL OFFICE16.44GCEM CALIBRATION LAB59.85BHD25.26DCM69.17SHINKAWA18.98SHINKAWA OFFICE27.39SHINKAWA STORAGE81.910SYSTEMS45.911DCS36.812DCS STORAGE21.113DCS OFFICE16.814DCS CUSTOMER10.515I TO P33.316SMART PRO CALIBRATION22.918VIBTRANS27.319SMART POSITIONER40.920WATER MONITORING45.5Total683.41882 International Journal of Current Engineering and Technology, Vol.7, No.5 (Sept/Oct 2017)
Varsha Karandikar et alLayout designing using Systematic Layout Planning for Electronics Division of a Manufacturing Facility4.1.GCEM WELDGCM CALIBRATION LABGCEM ASSEMBLYCODEL OFFICEBHDDCMSMART PRO CALIBRATIONSMART POSITIONERSMART PRO ASSEMBLYVIBTRANSI2PMany departments are manufacturing products whichare used as raw materials by other product divisions.As a result, there is high frequency of materialmovement between these departments. Therefore,these departments were placed close to each other inorder to reduce material handling. The overallmaterial handling between the raw material store andvarious departments and simultaneously from thedepartments to finished goods store has beenminimized.4.2.DCSSHINKAWASHINKAWA OFFICEDCS STORAGEDCS OFFICEDCS CUSTOMERSHINKAWA STORAGEWATER MONITORING SYSTEMSYSTEMSFigure 8 ALDEPGCEM CALIBRATION LABGCEM WELDWATER MONITORINGGCEM ASSEMBLYReduction in investmentsCertain departments require specific utilities, forexample GCEM Weld department has an individualcrane installed for loading and unloading of products.Similarly, many departments also required specificutilities like hydro test rig, pneumatic pressure lines,rigs and piping system etc. Therefore, the team foundit wise to keep the initial configuration intact in thefinal layout so as to keep the expenses low.4.3.15mReduction in material handlingEfficient use of spaceOriginally in 2760m2 of space the various departmentswhich exist today were placed as and when they wereintroduced in a tetris - A type of game where blocksare arranged in haphazard manner - like fashion. So,the team realized that the departments were using thespace in a highly disorganized and inefficient manner.Therefore, the layouts developed were evaluated insuch a way there was optimal utilization of space.CODEL OFFICEVIBTRANS4.4.DCMSMART POSITIONERI TO PSMART PRO CALIBRATIONBHDSMART PRO ASSEMBLYSYSTEMSSHINKAWADCS CUSTOMERDCS OFFICESHINKAWA STORAGEDCS STORAGEDCSSHINKAWA15mFigure 9 CORELAP4. ResultsThe layouts which have been developed using thecomputer aided algorithms, ALDEP and CORELAPwere evaluated on the basis of numerous criteriawhich were found relevant to this paper.Environmental ImpactSince the layouts have been prepared for the‘electronic division’ most of the productsmanufactured within, use PCBs. PCBs require a dustfree environment with regulated temperature. Sooriginally some part of the layout was subjected totemperature control and dust free environment.However, this isolated region was not sufficient forstoring PCBs for all the departments. Concurrentlymost of the production required precise job workwhich further demanded the operators to be highlyfocused. However, only a few operators weresubjected to this favorable condition. Therefore, tocounter this problem, with management’s approvalthe team decided to expand this isolated area. It wasalso beneficial for the new departments which were tobe added.4.5.Original Structure (columns/waterworks)The placement of department had to be done keepingin mind the original structure of the facility that isvarious columns, exits, entrances, electric andplumbing connections etc. This consideration was keptin mind while evaluating the layouts.1883 International Journal of Current Engineering and Technology, Vol.7, No.5 (Sept/Oct 2017)
Varsha Karandikar et alLayout designing using Systematic Layout Planning for Electronics Division of a Manufacturing FacilityConclusionReferencesIt is obvious that layout optimization task is crucial toany facility planning and layout study (Grajo, 1996). Ifnot tackled in the early phases, it can generate logisticsimplications for the company involved. Instead ofselecting from either of the two layouts, the teamextrapolated the advantages of each layout anddeveloped a new layout which was considered to bethe most optimal layout.Chee Ailing, Facility Layout Improvement using SystematicLayout Planning (SLP) and Arena, 2009James Tompkins, John White, Yayuz Bozer, FacilitiesPlanning, Willy, Fourth Edition ,2010R. Paneerselvam, Production and Operations Management,Prentis All India Learning Private Limited, Third Edition,2012Richard Muther, Systematic Layout Planning, CBI PublishingCo Inc, US, First Edition, 19731884 International Journal of Current Engineering and Technology, Vol.7, No.5 (Sept/Oct 2017)
Relationship Layout Planning (CORELAP). ALDEP is construction based algorithm and is used when activity relationship is a major consideration. It develops a layout design by randomly selecting a department and placing in the layout. The departments are placed in layout based on its closeness rating.
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Oct 30, 2014 · EE501 Lab 6 Layout and Post-layout Simulation Report due: Oct. 30, 2014 Objective: 1. Practice analog layout techniques 2. Practice post-layout simulation Tasks: 1. Layout the two stage amplifier designed in Lab 4(As shown in Fig 1) Common centroid layout of the fi
Systematic Layout Planning is a method used to produce a facility layout design with the most efficient flow of goods. This method puts forward the sequence of work processes and the degree of closeness between service units contained in the facility to be designed. The stages of the layout design process can be
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Black holes have entropy S. Black holes have Hawking temperature T H, consistent with thermodynamic relation between energy, entropy and temperature. Thermodynamics S A 4 where Ais the area of the event horizon. T H 2 ˇ where in the surface gravity of the black hole. Luke Barclay Durham, CPT luke.barclay@durham.ac.uk Supervisor: Ruth GregoryBlack Holes, Vortices and Thermodynamics. Path .
