Improvement Of Facility Layout Using Systematic Layout Planning: A Case Study Of Numerical Machining Complex Limited

ABSTRACT

The facilities layout problem is an integral part of facilities planning that aims to systematically arrange and locate all production units within a facility with an objective of improving the production operations of a company. Numerical Machining Complex is planning to improve the production of its manufacturing operations in its machining and fabrication workshop. It seeks to enhance the performance of the existing workshop in terms of efficiency, productivity, and space utilization. It endeavours to adopt a layout strategy that is flexible and able to accommodate its future production needs with a desire of having a well designed and improved layout that maximizes the production capacity of all its facilities. The main purpose of this research is, therefore, to develop an improved model using Systematic Layout Planning procedure to enable Numerical Machining Complex to create and effectively evaluate facility layouts. To achieve this initiative, existing traditional layout procedures were discussed and gaps identified. A model was then developed, consisting of six phases used sequentially to design, improve and evaluate facility layouts. Data on the company’s production processes was collected, flow analysis conducted, and three alternative layouts generated. The developed alternative layouts were evaluated, and compared with the existing layout. A suitable layout alternative was finally selected. The flow analysis developed relationships between activities across the workstations and identified the key areas of improvement in the existing layout. The suggested improvements aided in the development of new layouts. Based on a multi-criteria decision analysis of the developed alternatives, layout 1 was selected. The selected layout has lower rearrangement costs and a better priority score, though it slightly increases material handling costs by 3 per cent. It improves the safety of the existing layout of the company, offers flexibility, improves the flow of materials and people, and utilizes space efficiently. The developed model includes rearrangement costs which are not included in the Systematic Layout Planning model. In practice, the model helps Numerical Machining Complex to develop new layouts and the author recommended that the company should use it to study the process flow of materials and people, consider the generated layouts and implement the preferred one. They should also eliminate all the machines that have broken down in the workshop for improved flow.