Professional Documents
Culture Documents
Layout Design For A Low Capacity Manufacturing Line
Layout Design For A Low Capacity Manufacturing Line
Layout Design For A Low Capacity Manufacturing Line
Filippo De Carlo1,*, Maria Antonietta Arleo2, Orlando Borgia1 and Mario Tucci1
1 University of Florence - Department of Industrial Engineering
2 Politecnico di Milano - Department of Management, Economics and Industrial Engineering
DOI: 10.5772/56883
© 2013 De Carlo et al.; licensee InTech. This is an open access article distributed under the terms of the Creative
Commons Attribution License (http://creativecommons.org/licenses/by/3.0), which permits unrestricted use,
distribution, and reproduction in any medium, provided the original work is properly cited.
Abstract The layout re‐arrangement of fashion production Keywords Layout Design, Systematic Layout Planning,
lines realizing many small batches is rarely deployed Lean Production
according to well‐known engineering procedures. In fact, it
would often appear too complex to call a plant engineer for
the proper layout design of such small production lines. 1. Introduction
Rather, it is preferred to apply empirical methodologies
when considering, generally, factory know‐how, general One of the main goals of a manufacturing system is the
business needs, safety requirements, and so on. In the maximization of its productivity. This depends upon
present work, the results of a fashion manufacturing line several factors, such as the kind and the complexity of the
re‐layout were compared by analysing the current situation product made, the quality of the raw materials, the
with the solutions provided by a ʺhomemadeʺ company complexity of the manufacturing process and the
design, both through a systematic layout planning arrangement of the workstations constituting the
approach and a broader lean reengineering activity. production process. Some of these parameters are
determined by the product and, for this reason, are
In order to evaluate the effectiveness of each solution, the unchangeable; others, however, are variable and thus
different alternatives were compared with the help of a improvable. The challenge of determining the best
discrete event simulator, analysing productivity, arrangement of the workstations is one of the elements
transportation times and costs. The result of the case that has a great impact on system performance. It is
study showed a slight advantage with the lean approach known as the “facility layout problem”[1], namely the
in considering such efficiency indicators. In addition, the problem of the arrangement of everything that is
lean production methods allowed the designers to required for the production process. A facility, in fact, is
identify some inefficiencies that other approaches could any element that simplifies an activity’s execution, such
not see, since the latter did not focus on production in a as a machine tool, a work centre, a division, a
holistic way. manufacturing unit, and so on [2]. The literature gives a
To design or re‐design the facility layout of a The relationship diagram, which derives from the
manufacturing process, it is possible to apply many relationship chart, allows the consideration of alternative
different methods. Each one is based on a specific idea layout configurations. Among them we will find the best
and goal to be achieved. Since a method usually gives an solution, chosen considering more than just factors of
optimal layout configuration different from the others, it economy, such as the improvement of material flow and
is important to have a performance measurement tool in waste reduction, etc.
order to gain hints about the best method to adopt. This
2.2 Lean facility layout system
comparison could be made through a score, such as the
total closeness rating index [28], or a simulation analysis Lean manufacturing is a production system born in Japan,
highlighting the results of the main production process based on the Toyota Production System. This was founded
parameters, such as costs, times, the throughput rate, the on certain central ideas: the most significant are total quality
WIP or the line availability [29] [30] [31]. management, total productive maintenance and the ‘just in
time’. The first is related to the quality of the product, of the
Before investigating the best facility layout design process itself and of each element related to the production
method, we present in this section some of their major process. The second refers to the strategic role of
features, especially those of the systematic layout maintenance activities, while the last refers to the
planning (SLP) technique [32] and the layout suggested optimization of the logistic flow so as to decrease stock
by the wider activity of “lean” redesign, through the levels. The central idea of lean manufacturing is waste
value stream mapping tool. elimination [33] [34], which is essential to increase
www.intechopen.com Filippo De Carlo, Maria Antonietta Arleo, Orlando Borgia and Mario Tucci: 3
Layout Design for a Low Capacity Manufacturing Line: A Case Study
profitability. The elimination or reduction of waste, in fact, is of waste, such as transporting time, space and
oriented towards both efficiency and quality. unnecessary workstations.
Figure 4. Plan of the felt hat facility. On the left side is the actual
configuration of the main departments, while on the right is the
new building made available for the production and finishing
operations.
www.intechopen.com Filippo De Carlo, Maria Antonietta Arleo, Orlando Borgia and Mario Tucci: 5
Layout Design for a Low Capacity Manufacturing Line: A Case Study
pumicing, in fact, are “dirty” operations because they Among the alternative solutions, the most impressive
produce pollution during the fur processing. Dying is layout was chosen. The selection technique was the factor
another operation that is classifiable as “dirty” analysis method, which identifies the principal desirable
because of the use of chemical substances. By closely features (factors) for the new layout. The main factors
positioning these operations, it might be possible to considered were: worker flow; process flow; flow
have a unique air vacuum and purification system. visualization; possible expansion; interaction among
On the other hand, steeping and drying are strictly departments; grouping of equipment; flexibility. Each
related for technological reasons. The hat’s final factor has a weight representing its importance. A score
quality, in fact, also depends upon the time passing was assigned to all the layouts identified for each factor.
between these operations: in fact, it must not be too Next, it was multiplied for the weight of the respective
long. Moreover, for stiffening and finishing there is factors. Finally, each solution received its total score: the
an organizational constraint. These operations are layout with the best total value was the preferred layout.
directly related to the visual quality of the hat and use Figure 6 shows the selected empirical layout.
similar machines for final quality control. For this
reason, they should be placed close together. This result combines product and process layout features.
Raw materials’ availability: raw materials and The workstations, in fact, have a U‐shaped configuration
accessory elements are stored in three different areas, that follows the sequence of the manufacturing process
two of which are very far from the blowing station. activities. However, machines with similar features are in
Disorganization of tool arrangements: all the the same zone. The new layout partially follows the main
accessory elements used in the production phases workstations’ unification requirements, according to the
have a messy arrangement. reasons presented in section 3: steeping and drying are
nearby, and stiffening and finishing are neighbours in the
4. Results same area.
The manufacturing process re‐design was made through The empirical layout also facilitates a reduction of the
three different methodologies. The first one is an distance between the final phases (stiffening and
empirical method while the others are engineering finishing) and the other workstations. At the same time,
techniques. In the following sections, the results of each the tool arrangement was reorganized in a unique area.
method will be summarized. This first new layout thus seems to provide important
improvements to the production system.
4.1 Empirical approach
4.2 SLP
The first layout was identified empirically. According to the
problems recognized and the goals sought, various different The first step of a layout redesign with SLP is the
solutions have been suggested in an attempt to place similar construction of a relationship chart. The buff diagram
operations or activities with specific needs close together.
Figure 9. Layout obtained with the SLP method: eight operations Figure 11. Future value stream map. The main time reductions
out of the total of eleven are organized sequentially, while two of are related to the raw materials’ processing times and the final
the operations have a woven path. transportation and waiting activities.
www.intechopen.com Filippo De Carlo, Maria Antonietta Arleo, Orlando Borgia and Mario Tucci: 7
Layout Design for a Low Capacity Manufacturing Line: A Case Study
Figure 10 shows the value stream map of the “as is” state, Orders
Throughput Workers Yearly
from which the future and desired layout was obtained. fulfilled
time moving revenue
per year
[%] time [%] [€/y]
[#/y]
The future value stream map is shown in Figure 11. It is
Empirical ‐ 2.95% + 8% ‐0.25 ‐500
possible to note that the main changes concern the reduction
SLP ‐ 3.9% ‐ 15% +1.8 +3,600
of waiting times between the final operations and the
Lean ‐ 4.15% ‐ 24% +3 +6,000
reduction of the processing time for the raw material. In the Table 1. The layouts’ production performance. The table shows
desired configuration, there is also a new storage area for the production efficiency performance of each layout tested in
semi‐finished products between the two final workstations. comparison to the actual layout’s performance.
The layout obtained through this lean approach is shown To examine the productive performance of every layout,
in figure 12. As is clearly visible, this new layout offers a discrete event simulation was performed. The
many benefits, since it derives from an overall redesign of simulation model allowed us to analyse the efficiency of
the felt hat manufacturing process. One of the most each layout through its quantitative results. For each
representative elements is the presence of cells: the three layout configuration, a corresponding simulation model
operations of steeping, drying and dying are grouped was realized, generating many important productive
into a cell and, therefore, the operator of these activities parameters such as: the production time, the operator
can work in a smaller, more ergonomic area than before. waiting time, the ratio between throughput time and value
This causes a significant reduction of the transportation of added time, the number of annual orders, and so on.
waste, which is a no‐value added time. Furthermore, this
new layout enables for easier blocking and pumicing, Table 1 summarizes the simulation results of some of
since they are grouped and organized into two parallel these parameters.
lines. For this layout, and similar to the previous results,
the workstations are organized sequentially according to Table 1 highlights the following elements:
the manufacturing process flow. The advantages of the The production time (the sum of all the times
previous layouts are proved here again. necessary to make a felt hat, from the first operation
on the raw material to the last packaging phase) is
barely conditioned by the chosen layout. The transfer
operation times, which are a direct consequence of
the layout configuration are in fact very low when
compared to the production time. The lean layout
ensures the best production time reduction, because
it better respects the operation sequence.
The lean layout enables the fulfilment of 1,381 orders
a year, 13 more than the value reachable with the old
workstation configuration.
The annual turnover increases by €5,722 compared with
the value estimated with the old layout. In contrast, the
empirical layout causes a decrease of this parameter.
www.intechopen.com Filippo De Carlo, Maria Antonietta Arleo, Orlando Borgia and Mario Tucci: 9
Layout Design for a Low Capacity Manufacturing Line: A Case Study
[30] F. De Carlo, O. Borgia, and M. Tucci, “Risk‐based [35] Y. Monden, Toyota production system: an integrated
inspections enhanced with Bayesian networks,” Proc. approach to just‐in‐time. Productivity Pr, 2012.
Inst. Mech. Eng. Part O J. Risk Reliab., vol. 225, no. 3, [36] P. Hines and N. Rich, “The seven value stream
pp. 375–386, 2011. mapping tools,” Int. J. Oper. Prod. Manag., vol. 17, no.
[31] F. De Carlo, O. Borgia, and M. Tucci, “Accelerated 1, pp. 46–64, 1997.
degradation tests for reliability estimation of a new [37] T. Ōno, Toyota production system: beyond large‐scale
product: a case study for washing machines.,” Proc. production. Productivity Pr, 1988.
Inst. Mech. Eng. Part O J. Risk Reliab., in press. [38] X. Lu, Z. Jia, J. Yang, and H. Liu, “Design and
[32] R. Muther and A. H. Mogensen, “Systematic layout implementation of Lean Facility Layout System of a
planning,” 1973. Production Line,” Int. J. Ind. Eng. Theory Appl. Pr.,
[33] J. P. Womack, D. T. Jones, and D. Roos, The Machine vol. 18, no. 5, 2011.
That Changed the World: The Story of Lean Production‐‐ [39] M. Rother and J. Shook, Learning to See: Value‐Stream
Toyota’s Secret Weapon in the Global Car Wars That Is Mapping to Create Value and Eliminate Muda: Version
Now Revolutionizing World Industry. Simon and 1.3 June 2003. Lean Enterprise Institute, 2003.
Schuster, 2007.
[34] J. P. Womack and D. T. Jones, Lean Thinking: Banish
Waste and Create Wealth in Your Corporation. Simon
and Schuster, 2010.