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The Research on Discrete Manufactures for the Optimization about the Production Plant Layout

Author: FengBin
Tutor: LvMingZhe
School: Dongbei University of Finance
Course: Logistics Management
Keywords: Discrete manufactures Workshop layout optimization Simulation
CLC: TB491
Type: Master's thesis
Year: 2013
Downloads: 5
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Abstract

Now the manufacture is facing the different challenge with the development of the economy. To be worse, the challenge point is turning from the technology to the management. Especially for the global crisis, the manufacture is facing the challenge that it never happened with the cost of the row materials is rising,the salary of the workers is rising and the requirements of the customs is getting higher. While the profits of the manufacture are falling, now many manufacture company turn their point to how to decline their cost. Because the discrete manufacture have its own feature, it is difficulty to create the produce system which have the conveyors so that lead to stock more WIP and more inventory.it is not only occupy a lot of the money and but also the main reason of the low efficiency, at the same time it make the factory management get harder and harder. To be a word, the layout of the discrete manufacture is becoming the research point in the manufacture field.A good layout can add the competitive advantage of the company. While the cost of the layout only occupies2%-5%of the whole costs, it has the huge effects for the produce system. According to the statistics, the transport cost is occupying20%to50%, the good layout can directly reduce the cost of the transport about30%. Besides, the workers will know their responsibility and when and where to help the others in a good layout. So, the good layout can reduce the WIP, short their produce time, reduce the safety accidents and the cost of the manufacture.This paper takes the S company as the background. By comparing the way, comparing the lean way, the systematic layout planning way and the based DBR ways. In the lean way, after analyzing the current value stream map, find outing the problems and reasons. During the design of the value stream map, this paper take the U cell into consideration., which creates a small U cell with some zone that has the same produce capacity. In the systematic layout planning way, after analyzed the logistic reasons and no-logistic reasons, then decide the level, the cell relationship map, the table of the logistic intension. Finally, the second layout comes out with the Workshop integrated relation graph and Operation department close to scale. In the based DBR ways., based on the theory of constraints, considering to the border of the workshop layout constraints and safe distance between the various processing areas such as constraint conditions, and set up a buffer area before the bottleneck process workspace, taking the logistics cost minimizing the objective function, using the genetic algorithm to solve the optimal layout scheme In order to find out which layout is the best one, This papers use the Extendsim software to run out the model and compare them. It can prove that the based on DBR Way is better that the VSM ways and the SLP ways.

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CLC: > Industrial Technology > General industrial technology > Industrial common technology and equipment > Factory, workshop > Planning and Design
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