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Layout Design for New Production Line

Author: CaoPing
Tutor: YangLei；YangXiaoGuang
School: South China University of Technology
Course: Industrial Engineering
Keywords: Facility design and plan Facility layout Factory design Lean design
CLC: F426.8
Type: Master's thesis
Year: 2011
Downloads: 221
Quote: 0
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Abstract


More and more attention was paid to the facility layout design, with the changing marketing environment. No matter it’s rebuilding, expansion or new setup, facility layout design is essential, especially for the manufacturing. The factory needs to finish the planning and implementation within a short period of time. The layout design is not only related to the investment, but also influencing the running cost and productivity. So many designers are searching for an efficient and good layout plan.Company A is a lens manufacturer with 10 years of history. With the increasing of marketing demand, the original design can not fulfill the requirement any more. The re-building is at hands. The advantage and disadvantage of the current production line are obvious. So in this paper, we analyze the situation of the existing line, and provide a new efficient and reasonable layout plan with lean production theory, in order meet the production demand.We described the concept and development of facility layout design, as well as the lean methods. The combination with the theory of facility layout planning and the lean designing efficiently support the lean layout design. Before the new layout design, we investigate the strength and weakness of the current line. It’s found that the lagging machines have wasted a lot. So it’s re-designed again in this paper: with ultrasonic cleaning instead of the manual one; sorting machine instead of the two steps sorting achieving the multi-production with different productions; auto- packing instead of manual packing. The new design increased the efficiency a lot. However, there is still some problem like isolated island production and the low efficient moving. In order to further eliminate the waste, the project team find out the compensation data with several rounds of comparative experiments. The post curing is relocated after edging from before, to achieve the maximum flow of production. We fully evaluate the material handling system and the tools, taking use of the lean production method, to make the entire production line running in the most efficient way.Through the re-design and implementation of the production line, we found out the way to combine the layout design and the lean method. The waste could be eliminated before the layout design, laying solid foundation for the lean management.

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