Journal of Advances in Science and Technology

Vol. 13, Issue No. 01, (Special Issue) March-2017, ISSN 2230-9659

Case Study on Improvement in Plant Layout

Design

Devashri D. Thakre1*, Uday A. Dabade2

1
PG Student, Walchand College of Engg., Sangli, Maharashtra, India
2
Professor and Head, Department of Mechanical Engineering, Walchand College of Engg, Sangli, Maharashtra,
India

Abstract – Layout problems are found in every industry with variety of types. They are known for
impacting the system performance. So it is important for industries to improve the plant layout design
and simultaneously take into consideration to reduce their cost and expenses involved so as to survive
in the competitive world. There are number of solution techniques available to optimize plant layout
design. Lots of research papers and many of literature reviews exist on these variety of techniques
developed by many of researchers till now, but they are restricted to certain specific aspects of the plant
layout problems. This paper will give the complete idea about the plant layout design without any specific
consideration. The paper includes understanding of plant layout and its types, location problems,
formulation methods of those problems, methodologies and simulation techniques. In the end complete
process is summarized so that anyone interested in this area can choose best suitable technique that can
be implemented to the particular case and start working on it from the basics. This paper will guide at a
macro level to understand all aspect of plant layout design.

Case study taken in this paper is of one of the MNC. Systematic Layout Planning (SLP) method has been
applied which gives solution in terms of minimized travelling distance and reduced material handling.
Analysis of previously designed layout and final layout came out of Systematic Layout Planning (SLP)
showed that material flow throughout the plant area is reduced by 38.2% and additional 70 square meters
of area is created for kitting.

Keywords: Plant Layout Design, Formulation Methods, Methodologies, Simulation Techniques,

Systematic Layout planning.

---------------------------♦-----------------------------

INTRODUCTION maximization of flexibility and maximization of factory

output in conformance. There are number of
Patil [1] defined plant layout as a designing best traditional facility layout design procedures. They are
structure to contain facilities which includes operating developed way back in nineties. Some of the
equipment, storage space, material handling methods are listed chronologically.
equipment, personnel and other supporting services.
Each plant layout design is unique by its particular  Naddler‟s Ideal System Approach (1961)
assumptions, constraints, limitations, and the intrinsic
activity of the components said by Vollman and Buffa  Immer‟s Basic Steps (1950)
[2]. Shayan and Chittilappilly [3] defined the facility
layout problem as an optimization problem that tries to  Apple‟s Plant Layout Procedure (1977)
make layouts more efficient by taking into account
various interactions between facilities and material  Reed‟s Plant Layout Procedure (1961)
handling systems while designing layouts. Azadivar
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and Wang [4] defined that the facility layout problem  Muther‟s Systematic Layout Planning (1961)
as the determination of the relative locations for, and
allocation of the available space among a given
number of facilities. Huang [5] states that facility layout
design determines to arrange, locate, and distribute
the equipment and support services in facility to
achieve minimization of overall production time,

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Devashri D. Thakre1*, Uday A. Dabade2
 Case Study on Improvement in Plant Layout Design

LITERATURE REVIEWS: FACILITY LAYOUT B. Facility Layout Problems (FLP)

DESIGN
The placement of the facilities in the plant area, often
A. Types of Layout referred to as „„facility layout problem‟‟, is known to
have a significant impact upon manufacturing costs,
The choice of type of facility layout can have a work in process, lead times and productivity. Drira et
significant impact on the long-term success of a firm. al proposed rough tree representation of layout
This decision, therefore, should not be considered problems and different factors taken into account in
lightly, but only after a thorough analysis of the their literature [8].
operational requirements has been completed. There
are various methods of grouping and production A plant layout problem may be associated with either a
machinery, the common and classical types of the single objective or a multiple objective. However, real-
arrangement are fixed position layout, process layout life plant layout problems are often associated with
and product layout, but most plants today are laid out multiple objectives, such as minimization of total flow
using a combination of these classical layouts and are cost, maximization of total closeness rating (TCR), etc.
never seen in their pure form. Dixit and Dev focused A multiple-objective facilities layout problem can
upon these different layouts and their efficient therefore be defined mathematically as the optimum
utilization in the production industries. This is very assignment of facilities to locations so as to achieve
useful to fetch the best layout for different existing the objectives stated for the layout problem. These
condition of the industries [6]. objectives can be classified into following two
categories: Conflicting objectives, such as
The efficiency and productivity depends on the type of minimization of TFC and maximization of TCR and
manufacturing layout is being used for production of safety, and congruent objectives, such as
goods and services. minimization of distance-weighted cost of several
attributes, viz. flow, closeness rating, etc. [9].

C. Formulations

Once the problem is identified and the type of layout

to be designed is decided, formulation of problem
comes into the picture. Formulation is done generally
in terms of objectives such as minimization of cost
associated or time, maximizing the closeness
between the departments, etc.

Different models that are developed to formulate

layout designs are:

1) Quadratic assignment problem (QAP 1957):

The name was so given because the objective

function is a second degree function of the variables
and the constraints are linear functions of the
variables. Required parameters are number of
locations, flow of material from one location to other,
cost associated with this transportation. QAP is of two
kinds, linear assignment problem and travelling
salesman problem [10].

2) Linear integer programming problem (LIP 1963):

Integer programming problem and the QAP are

According to Singh [7], not only efficiency is increased equivalent. The difference is that this type requires
directly but indirectly good facility layout also more memory for formulation i.e. more variables and
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contributes to efficiency by reducing accidents, constraints are involved than that of QAP model [10].
hazards, by increasing easiness and convenience.
Most importantly a better facility design allows smooth 3) Quadratic set covering problem (1975)
function of manufacturing. Based on the literature
studied, table 1 describing comparative study of all In this formulation, the total area occupied by all the
kind of facility layout is made which will be helpful in facilities is divided into a number of blocks. The
identifying given layout and the appropriate type of distance between the locations is to be taken from
layout it would have been. centroids of the locations. Disadvantage is that the
228
NC – MEND 2017, Organized by Govt. College of Engineering, Karad, Maharashtra
In Association with The Institution of Engineers, PLC
 Journal of Advances in Science and Technology
Vol. 13, Issue No. 01, (Special Issue) March-2017, ISSN 2230-9659

problem size increases with the total area occupied by strategy for obtaining approximate solutions and thus
all the facilities is divided into smaller blocks. It is not are widely applicable to various forms of combinatorial
suitable for problems with nine or more facilities [10]. optimization problems [13-14]. From the literature
methodology is summarized in figure 1.
4) Graph theoretic problem (1976)
Levary and Kalchik [15] have characterized most used
This model is based on a predefined desirable solution procedures for facility layout problems.
adjacency of each pair of facilities. Used mostly for the Characteristics include input required, type of output
construction type layout design process [11]. obtained, advantages features and limitations. All the
techniques are tabulated according to their
5) Mixed integer programming problem (1978) characteristic very systematically. This survey paper
will guide to adopt the appropriate method for a given
Linear mixed integer program has the smallest number layout.
of variables and constraints amongst all integer
programming formulations of the QAP. This type of
model is applicable to evaluate the performance of
solutions for the problem having more than one
objective [10].

D. Methodologies

In this section various solution methodologies, e.g.

exact procedures, heuristics and meta-heuristics
available to solve facility layout problems optimally or
near to optimal are explained.
Fig. 1 Methodology
Exact method is used to find an optimum solution of
quadratic assignment formulated Facility Layout
E. Simulation Techniques
Problem (FLP). QAP involves only binary variables.
Only optimal solutions up to a problem size of 16 are
reported in literature. Beyond n=16 it becomes Application of a simulation model is to assist decision
intractable for a computer to solve it and, making on expanding capacity and plant layout
consequently, even a powerful computer cannot design and planning. The plant layout design
handle a large instance of the problem. concept.is performed first to create the physical
layouts then the simulation model used to test the
capability of plant to meet various demand. Table 2
A heuristic is a technique designed for solving
shows the various software packages and their
aproblem more quickly and finding an approximate applications as per requirement of results [16].
solution when classic methods fail to find any exact
solution. Heuristic algorithms can be classified as Table 2 Simulation Software Packages [16]
construction type and improvement type. Construction
based methods are considered to be the simplest and Type of analysis Simulation software
oldest heuristic approaches to solve the QAP. Block Layout -FACTORYOPT
Improvement based methods start with a feasible -WINSABA
solution and try to improve it by interchanges of single -SPIRAL
assignments. Improvement methods can easily be -CRIMFLO
combined with construction methods [11 - 12]. -MALAGA
-MATFLOW PLAN OPT
STORM
A metaheuristic is a higher-level procedure or
Group Technology -PROFILIER MINITAB SAS
heuristic designed to find a sufficiently good solution to PDM Products
an optimization problem, especially with incomplete Material Flow Analysis -FACTORYFLOW PFATS
data available. Metaheuristics sample a set of Process Flow Mapping -VISIO
solutions which is too large to be completely sampled. -OPTIMA
Metaheuristics may make a few assumptions about the -SIMULB
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-ARENA
optimization problem being solved, and so they may
Visualization and -PROMODEL
be usable for a variety of problems. Arostegui, et al. Performance -WITNESS
classify heuristics methods into tailored and general. Evaluation -MPX
While tailored heuristics have a limited applicability to -TAYLOR II
a specific problem, general algorithms define a -QUEST

Devashri D. Thakre1*, Uday A. Dabade2 229

 Case Study on Improvement in Plant Layout Design

-FACTORYPLAN CASE STUDY: IMPROVEMENT IN FACILITY

Multi-criterion -EXPERT CHOICE LAYOUT
Evaluation of Layout -SUPERTREE
Alternatives
Economic Analysis of -EASY ABC
Plant remanufacturing 5 types of products is taken as
Layout Alternatives a case study to redesign the layout. 5 products are
Capacity Planning and -LINDO Cylinder Head (CH), Turbocharger (TC), Water Pump
Sizing of Layout -GAMS (WP), Lube Pump (LP) and Cam Follower (CF).
Alternatives -CPLEX Accommodation of new product line in TC is one of the
-MPX major reasons for redesigning layout, General process
-FACTORY MODELLER for remanufacturing these products starts with core to
disassemble and then dismantled parts sent for
F. Summary cleaning followed by various salvaging processes and
finally product gets assembled. Material flow in the
From the literature studied the process that should be current layout is complex which results in higher
followed for plant layout design is summarized in the throughput time for all the lines. Current layout of the
figure 2. plant is shown in figure 3.

1. Select suitable type of layout for given plant

according to the requirement. For example for
Mass production or batch production select
type of layout by referring table 1 accordingly.

2. Specify objectives as per the company‟s

requirement. That may be minimization of cost
or maximization of closeness rating.

3. Formulate the objective according to the goal

set.

4. Whether the data collected is small or large

decides the method to be applied to design the
layout. The quality of the solution i.e. exact Fig. 3 Current layout
solution or near to optimal solution is taken
into consideration as well. A. Objectives

5. For the verification of solution we have got, Most of the times there is a case in plants that,
implementation of simulation technique is current plant space is fully occupied and it was
necessary. designed according to previously required production
and now in future it is required to change as the
business grew. So in such cases making space
available is tough task. So according to the
requirement of the company following objectives are
taken into consideration.

i. Minimize material flow

ii. Maximize adjacency score/ closeness rating

between the cells where there is requirement

B. Systematic Layout Planning (SLP)

Systematic Layout Planning (SLP) shown in figure 4,

is widely used for layout design. It is constructive type
of method used to design new layout for the plant
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which will have higher productivity at less material

flow throughout the plant. SLP consist of 10 steps
which are divided into three phases, viz., Analysis,
Search and Evaluation.

Fig. 2 Summarized methodology of layout design

230
NC – MEND 2017, Organized by Govt. College of Engineering, Karad, Maharashtra
In Association with The Institution of Engineers, PLC
 Journal of Advances in Science and Technology
Vol. 13, Issue No. 01, (Special Issue) March-2017, ISSN 2230-9659

5 Post cleaning 25
6 CH Salvage 720
7 Quality 100
8 CH Assembly 520
9 FG 168
10 Storage 140

iv. Space relation diagram: Space relation

diagram is extension of the activity relation
diagram. It is to allocating area required to
each cell in activity relation diagram as
shown in figure 6.

Fig. 4 Systematic Layout Planning

Tools required: Fig. 5 Activity relation chart

i. Activity relation diagram: Activity relation

diagram shows closeness required between
every two departments. Input required for this
tool is activity relation chart. It is nothing but
chart showing all the closeness ratings and
reason behind that closeness rating as shown
in figure 5.

ii. Constraints: Cleaning cell includes section for

dirt removal, rust removal, paint removal etc.
it‟s a module of 5 sections having large tank
for filling up the chemical required. So cleaning
cell will be constraint during redesigning whole
plant.

iii. Detailed information about process flow and

cells: Table 3 includes all the product line cells
and the area occupied by them in square Fig. 6 Space Relation Chart
meters.
Final layout obtained from Systematic Layout
Table 3 Area Occupied By The Cells Planning (SLP) is as shown in figure 7.

Sr. No Area Occupied

Process 2
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(M )
1 Disassembly 185
2 Pre cleaning 25
3 Primary cleaning 200
4 Shot Blasting 200

Devashri D. Thakre1*, Uday A. Dabade2 231

 Case Study on Improvement in Plant Layout Design

i. Total closeness rating between the

departments is improved by 7.9%

ii. Total material flow in terms of weight*distance

flow minimized by 38.2%

iii. Space utilization: 70 square meters of extra

space created for kitting, sitting place shop
managers on floor area is created.

REFERENCES
Fig. 7 Proposed layouts
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In Association with The Institution of Engineers, PLC
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Vol. 13, Issue No. 01, (Special Issue) March-2017, ISSN 2230-9659

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Corresponding Author

Devashri D. Thakre*

PG Student, Walchand College of Engg, Sangli,

Maharashtra, India

E-Mail – devashri_thakre@yahoo.com
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Devashri D. Thakre1*, Uday A. Dabade2 233