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Layout Of A Manufacturing Facility

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Question:

Discuss about the Layout of a Manufacturing Facility.
 
 

Answer:

Introduction:

In order to ensure the effectiveness of the entire production and operations process the companies often design a framework of a manufacturing facility.  The layout often helps in maximisation of the capital profit and employee engagement. This essay is going to discuss about the important aspects of the layout, its objective, the theoretical discussion of the structure and factorial exhibition of the expected consequences. The essay designs a suitable layout for a precast manufacturing unit with the help of the principles of framework.

Every business company follows a certain goal structured for its business achievement.  In case of setting the goals for manufacturing operations, the companies often design a linear layout for manufacturing facility. Before comprehending the layout, one needs to understand how it is defined. The facility layout is nothing but a specific arrangement for understanding the varieties of dimensions of manufacturing process so that most suitable steps are initiated to enhance and improve the quantity and quality of production.

Goals and Objectives:

The primary objective of the layout is to provide smooth working environment to the employees so as to increase the level and quality of production or manufacturing. It also aims at creating a space where the agreements between the manufacturing process and manufacturing ideas can be placed together. Following are the outline work of the proposed and designed layout. 

i) Confirmation of the acceleration of the product order

ii) Ensuring the safety and security of the working employees

iii) To lift up the capacity of production

iv)To provide facility to the technological upgrade and introduction of new product line.

v) To grab hold of the swaying workers and raw materials

vi)To ensure the fixity of the product equipments

In order to achieve the aforesaid objectives, one needs to consider the effective factors behind the formation and design of this layout. The framework of the layout is constructed in accordance with the basic design principles. The structure also follows utilisation of space and capital and flexibility of the organisation because without firm consideration of these factors, it is quite tough for an organisation to design a proper layout.

Structural Description:

Development of the layout depends on line balancing method as it aims at assembling the basic materials for manufacturing. The strategy of line balancing has two dimension of structure: static balance and dynamic balance. Static balance is related to the differences of capacity in long term performance whereas dynamic balancing refers to the differences in capacity in short term basis. Mix variation of the products and work time variety are not related to the value of the product mix. Product line stability is intended to facilitate the competence of the workers and utilisation of the existing equipment. In general, the line balancing approach is counterproductive. It happens because of the automatic ensemble of potential utilisation and high inventory.

 

Type of Facility Layout:

Since the proposed layout is one made with multiple combinations, it is going to be the amalgamation of size and type of the firm. The combination is no doubt apt for almost every type of product (especially tangible). The sequence of the operations for different product ad size remains almost the same because the layout is applicable irrespective of the types of products it deals with.

Process:

The process of layout begins with the laying out of the rebar. It is associated with the raw materials required for it. At first, the rebar is cut and is moved to the next level. In the second step, the rebar is bent and shaped properly. In the next step, the rebar is transferred to the bed of casting. In the meantime, cement, sand, and other essential materials are mixed properly so that it becomes a perfect mould. After ensuring proper mixing process, it is poured to the casting bed. It is further added to the cast concrete and rebar. The work of formation is adjusted according to the proposed shape. After the final component is cured, the precast is ready for the usage.

Diagram:


The AON:

PERT and CRM approaches will be beneficial for the project management and resource allocation (De Carlo et al. 2013). According to them, the availability of the required resources is unlimited in the project network. However, the reality is quite different as the resources and time both are limited (Zhou et al 2014). It must be considered while establishing the schedule of the network. A balance must be maintained in the project schedule if the supply of the required resources are insufficient (Bracke et al. 2014). Proper allocation of the resources is highly responsible for the successful development of the project (Mourtzis and Doukas 2014). The initial stage of the project can be named as SI and the future state can be named as SF. There are three basic scenario that may occur:

  • It can a smooth procedure to move from SI to SF.
  • The progress of the project can be stopped between the two basis states of a project development (SI and SF).
  • There may be reversion of progress from SI to SF (Samy, AlGeddawy and ElMaraghy 2015).

Strategies are established to obtain the next stage of the project on the basis of resource allocation as the availability of the resource plays vital role for moving the project from the initial stage to the next level (Tolio et al. 2013). The key strategy for resource allocation is to divide the activity G between 2 technical staff members and activity A between 2 technical staff. This strategy is followed as activity G requires 4 members but activity A requires 2. However, due to having sufficient member activity A will be completed on time and the member can proceed for the next level. Thus, if the activity G take longer time, the projects development will not be hampered. This strategy will help to complete the project on time in spite of having insufficient staffs. The activity A does not need any extra equipments, so it will be delivered all the required fuel (50 liters). A will receive one support staff as the L does not need any support, but activity A must be completed on time. Activity B needs three days and four technical employees to be completed, but it will get only three staff members to be done. Activity L will get one technical staff instead of two staffs as there is enough time before the next activity after activity L. During this period activity B,C.D and E must be completed successfully. Activity L will be given hundred liters of Fuel, one extra equipment with five epoxy materials.

Activity C will receive two technical staff members and one support staff because the activity must be completed on time before proceeding for activity D. However, C will be given 35 liters fuel for finishing the task within two days. D will be allocated one support and one technical staff member and twenty liters of fuel. On other hand, activity E will receive support of three technical staff, two support staff. Task E must be done on time before starting task F. Activity K also must be done before activity F. The K activity will get six technical staffs. It is expected that activity H, K and E must be finished on time as all these task has received large number of support staffs and other required resources. After the completion of H and K  also F will not be able to start before the completion of E. Activity K will receive two technical support one support staff member  as it needs two days to be completed and no special equipments are required. H will be delivered one hundred eighty liters of fuel as the activity uses two special equipments. Activity H, K and E must be completed on time before starting activity F. Activity G and L can be allocated some expandable resources as there is long time duration between these activities and the next activity. Activity F will be getting all the required resources like twenty liters of fuel, support of six technical staff and support of three support staff members. This activity does not require the support of any extra equipment or epoxy, but the time span to complete the task is fixed. The activity F must be finished within two days. Support from all the technical staff and support staff member will be available during this two days.

Resources can be updated by real time tracking. Updated resources will be beneficial to achieve the target and enhance the performance (Moon et al 2014). Another important strategy to achieve the target to modify the group and maintain individual calendars and make a list of all the task to identify the changing priority. Re-allocation and updating of the resources can be helpful to maintain balance in the workload (Niroomand et al. 2015). All the team members must be provided three hundred Sixty degree transparent idea about the project to help them to understand about the project (Murthy et al. 2016). It will be helpful for them to observe the importance of their performance and to understand how they can contribute in the project development. They will be able to create their own strategy for achieving the target. Making business rules will also be beneficial to update the resources as it will help the management to monitor the performance graph of all the team members. These rules will inform team members about the time sheets and review the growth of their own performance (García?Hernández et al. 2015).

 

Reference:

De Carlo, F., Arleo, M.A., Borgia, O. and Tucci, M., 2013. Layout design for a low capacity manufacturing line: a case study. International Journal of Engineering Business Management, 5, p.35.

Zhou, Q., Wu, X., Xia, Y. and Cai, W., 2014. Spot weld layout optimization of tube crash performance with manufacturing constraints. Journal of Manufacturing Science and Engineering, 136(1), p.011014.

Bracke, S., Inoue, M., Ulutas, B. and Yamada, T., 2014. CDMF-RELSUS Concept: Reliable and Sustainable Products–influences on Design, Manufacturing, Layout Integration and Use Phase. Procedia CIRP, 15, pp.8-13.

Moon, D.H., Song, M.J., Park, C.S., Zhang, B.L. and Shin, Y.W., 2014. A Simulation Study on the Layout Design of Micro Assembly Line for Lens Module. IFAC Proceedings Volumes, 47(3), pp.1678-1683.

Niroomand, S., Hadi-Vencheh, A., ?ahin, R. and Vizvári, B., 2015. Modified migrating birds optimization algorithm for closed loop layout with exact distances in flexible manufacturing systems. Expert Systems with Applications, 42(19), pp.6586-6597.

Murthy, P.B.G.S.N., Ranganayakulu, J., Vidhu, K.P. and Rao, K.V., 2016. Heuristic Search Algorithm for the Single-row Machine Layout in an Automated Manufacturing System. Procedia Technology, 25, pp.1088-1095.

Mourtzis, D. and Doukas, M., 2014. Design and planning of manufacturing networks for mass customisation and personalisation: challenges and outlook. Procedia CIRP, 19, pp.1-13.

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