# Plant Layout Optimization

Topics: Cellular manufacturing, Jason Statham, Work in progress Pages: 22 (3009 words) Published: April 17, 2013
Figure 6.8. Initial Layout of Cell 1
The optimum sequence method starts with an arbitrary initial solution and tries to improve the layout by switching two departments in the sequence. At each step the method computes the cost changes for all possible switches of two departments and chooses the most effective pair. The two departments are switched in sequence and the method repeats. The process stops when no switch results in a reduced cost. The optimized facility information and layout have been shown below. Table 6.7 Optimized Facility Information of Cell 1

Department
Color
Area-required
Area-defined
x-centroid
y-centroid
Sequence
M41
1
11
11
9.13636398
8.77272701
1
M4
2
6
6
9
10.166667
2
M2
3
6
6
3
0.5
3
M31
4
14
14
8.71428585
11.7857141
4
M25
5
84
84
3.42857146
7.92857122
5
M7
6
6
6
9
7.33333349
6

Figure 6.9. Optimized Layout of Cell 1
The initial material handling cost of the layout was Rs.10550. The CRAFT algorithm is used for the optimization of machines in the Cell 1 layout. After performing six iterations the cost has been reduced to Rs. 5950 and the layout has been optimized. In the optimized layout the machines 25 and 7 needs to be switched/interchanged. 1.1.1. Machine Optimization in Cell 2

The procedure for doing the optimization is discussed in 6.7.1. The facility information, machine information, flow matrix, cost matrix, initial facility information and optimized facility information for Cell 2 is shown in Appendix F. The procedure for optimization of Cell 2 is same as that of Cell 1 and the results of the optimized layout is shown below. The result of the optimized layout is shown in the figure below.

Initial layout of Cell 2
Optimized Layout of Cell 2

Figure 6.10. Initial and optimized layouts of Cell 2
The initial material handling cost of Cell 2 layout was Rs. 6100. The iterations performed is only one and the cost has been reduced to Rs. 5600. The machines 9 and 38 needs to be switched for optimized layout. 1.1.2. Machine Optimization in Cell 3

The procedure for doing machine optimization is by using CRAFT and this has been discussed earlier. The facility information, machine information, flow matrix, cost matrix, initial facility information and optimized facility information for Cell 3 is shown in Appendix F. The result of the optimized layout is shown in the figure below.

Iniital Layout of Cell 3
Optimized Layout of Cell 3

Figure 6.11. Initial and Optimized Layouts of Cell 3
The initial material handling cost of Cell 3 layout was Rs. 7100. The iterations performed is only one and the cost has been reduced to Rs. 5672. The machines 18 and 19 needs to be switched for optimized layout. The layout is further optimized by switching the fitting and lathe area. Initial Layout of Fitting and Lathe area

Optimized Layout of Fitting and Lathe area

Figure 6.12: Initial and Optimized Layouts of Fitting and Lathe area The initial material handling cost of fitting and lathe area was Rs. 7700. The iterations performed is only one and the cost has been reduced to Rs. 7500. The fitting and lathe area needs to be switched for optimized layout. The machines 5, 6 and 15 are out of order and these are replaced with the machines 41, 38 and 25 respectively in the cellular layout. Machine 3 has also been moved to the initial position of machine 25. For optimizing the layout machines 18 & 19, 9 & 38 and 25 & 7 needs to be switched. The modified layout after optimization is given below.1

Figure 6.13. Optimized Cellular Layout

CHAPTER 7
SIMULATION EXPERIMENTATION AND RESULTS
7.1. Introduction
This chapter discusses about the simulation for the current and proposed layouts. The existing process layout and modified (Cellular) layout has been modeled using ARENA 10.0 simulation software. The results generated will be compared to the current layout and the best layout will be chosen. 7.2. Experimentation

The simulation...