Optimization of The Plant Layout in The Production
Optimization of The Plant Layout in The Production
Damir Belic
Assistant Production of the Special Transformers
University of Zagreb
Faculty of Mechanical Engineering and - Case Study
Naval Architecture
Croatia
This paper is a case study of the plant layout optimization in the
Zoran Kunica production of the special transformers. The continuous global crisis is an
Professor ideal time for companies to raise their efficiency, flexibility and trans–
University of Zagreb parency of their operations and competitiveness in the global market. One
Faculty of Mechanical Engineering and
Naval Architecture of the possibilities to improve these features is a reduction of internal
Croatia transport costs, based on the utilization of the company's own resources.
With optimal layout of the workplaces and the equipment, the transport
Tihomir Opetuk routes are shortened, thereby the employees’ time is reduced, transport
Postdoctoral researcher
University of Zagreb
means are released, production lead times are shortened and intermediate
Faculty of Mechanical Engineering and warehouses are reduced or closed. Because the employees’ time is
Naval Architecture reduced, they have more time to do something effective - what the buyer is
Croatia
willing to pay for. Also, with shorter production lead times, there is a
Goran Dukic faster material flow, less waiting and less opportunity cost of capital. The
Professor paper shows the steps that are necessary for the transition from the
University of Zagreb existing to the optimal layout of workspaces and equipment. Bloch-
Faculty of Mechanical Engineering and
Naval Architecture
Schmigalla triangular method is used for the optimization.
Croatia
Keywords: intralogistics, material handling, routing, triangular method,
performance analysis.
Following the completion of the calculation, the Transport output based on the current layout is also
material flow intensity matrix is made. The values calculated and that value is 897 distance units/planning
inside the matrix represent the transport intensity period, so it is evident that the current layout can be
between the k-th and j-th element of the system. As each optimised. Based on the amount of the manufactured
element of the system can be a source or a target point, products, the planning period used in this case study is one
the matrix is square. The material flow intensity matrix year. In this case study only the optimization of location
for default process is shown in Figure 4. was used based on existing limitations. Taking into account
Based on the data given from the material flow some management limitations that some elements of the
intensity matrix, the mesh of the equilateral triangles is system must remain in the current positions (in this case
created. First two elements which are assigned in trian– those elements are the control station and both dryers) the
gular mesh are the ones with the highest material flow new layout is proposed and shown in Figure 6. Also work–
between them; in this case they are assembling of the station 2 and workstation 3 are similar by their charac–
active part and control. Next elements assigned in the teristics, so workstation 3 can be excluded from the system
triangular mesh are defined by following the rules men– because considering the current amount of the products, it
tioned before in the text. Elements within the triangular is not necessary to use both workstations. Eliminating
mesh are labeled by numbers shown in the Figure 3. workstations 3 from the system and the redistribution of
(e.g. Workstation 1 is 1, Control is 9 etc.). The trian– the elements would enable extra space for storage of semi-
gular mesh of the default system is shown in Figure 5. finished and finished products (the area with hatch in
Figure 6). Therefore, taking into account the listed limi–
tations, the new minimum transport output is calculated
and that value is 787 distance units/planning period.
The actual value of transport output is calculated by
entering the actual distance between the elements (instead of
a unit distance in the triangular method). The value of the
transport output for the current state is 12554 m/planning
period and the value of the transport output for the optimal
layout (taking into account given limitations) is 9787
m/planning period. The results are shown in Table 1.
By redistributing of elements, the obtained savings
would be 2767 m/planning period for the current
amount of products. If the assumption is that the
Figure 5. Mesh of equilateral triangles [17]
average transport speed is 5 m/min, it is calculated that
Based on the layout of the elements given in the saving time for transport is 9,2 hours/planning period,
triangular mesh, the minimum transport output for and also by eliminating the Workstation 2 and
optimal layout is calculated: redistribution of the elements, a certain space is given
(in this case 42 m2) which can be used for storage or
f c = ∑ k =1 ∑ j =1 bkj × skj = 638
m m
(3) something else.