STAGE-I- PROJECT REPORT

on

"ESTIMATION OF EFFICIENCY RATE AND OPTIMIZATION OF PROCESS TYPE

PLANT LAYOUT FOR A PRODUCTION INDUSTRY USING MATLAB"

By

Balaji Naidu - 113A6037

Harikrishnan Nair- 113A6039
Varun Nair - 113A6041
Atish Shetty - 113A6055

UNDER THE GUIDANCE OF

Prof. ONKAR POTADAR

SUBMITTED IN PARTIAL FULFILLMENT FOR THE DEGREE OF

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

SIES GRADUATE SCHOOL OF TECHNOLOGY
NERUL, NAVI MUMBAI 400706
ACADEMIC YEAR
2016 2017

CERTIFICATE
This is to certify that this is a bonafide record of Project Stage-I of the project titled Title of
the Project carried out by the following students of final year in ---- Name of the Branch---.

Sr. No. Name Roll No.

1. Balaji Naidu 113A6037

2. Harikrishnan Nair 113A6039

3. Varun Nair 113A6041

4. Atish Shetty 113A6055

The report is submitted in partial fulfillment of the degree course of Bachelor of Engineering
in ---- Name of the Branch---, of University of Mumbai during the academic year 2016-17-
15.

Internal Guide Head of Department Principal

(Note: Add following format only when oral exam is mentioned in the syllabus)

We have examined this report as per University requirements at SIES Graduate School of
Technology, Nerul (E), Navi Mumbai on ____________.

Name of External Examiner: ___________________________________________

Signature with Date: _____________________________

Name of Internal Examiner: ___________________________________________

Signature with Date: _____________________________

 ACKNOWLEDGEMENT

We would like to express our special thanks and gratitude to our Guide Prof.Onkar
Potadar as well as our principal Dr.R.V Patil and our Head of Department Dr.Pradip Patil
who gave us the golden opportunity to do this project on the topic ESTIMATION OF
EFFICIENCY RATE AND OPTIMIZATION OF PROCESS TYPE PLANT LAYOUT
FOR A PRODUCTION INDUSTRY USING MATLAB, which provided a chance to
investigate on the topic and learn a great deal about them.
Secondly we would also like to thank our parents and friends for giving an helping hand
in the work of our project. We would like to thank our teaching and non - teaching staff
members of our college for their backing and encouragement in facilitating the work on this
project.

Project Group

Balaji Naidu

Harikrishnan Nair

Varun Nair

Atish Shetty

CONTENTS
 Sr.No. Topic Page No.
1. Abstract 5
2. Introduction 6
3. Need of Project 7
4. Literature Survey 8
5. Objective/Objectives 9
6. Methodology 10
i. Facility layout definition 10
ii. Systematic Layout Planning
11
iii. Facility under consideration
iv. CORELAP Algorithm 12
v. Genetic Algorithm Method
13
vi. Nonlinear technique
14
16
7. Data Collected 17
i. Current layout
ii. Product sequence 17
iii. From- to- chart
vii. Space relationship diagram 18
viii. Improved Layout
19

19
8. References 20

ABSTRACT

The project aims at developing a beneficial plant layout by optimizing the current facility
design by systematic layout planning method (SLP) and same using simulation in
MATLAB. One of the objectives is to arrange a workplace in a plant by locating areas with
high frequency and logical relationships close to each other. The existing layout is to be
improved and a cumulative solution will be designed by considering various parameters. The
process plant under consideration is a leading manufacturer of sub-woofers, woofers, full-
range speakers, etc. By optimization of process plant layout we achieve a growth in
productivity, decrease in cost per unit and saves precious manufacturing lead time. The
efficiency of production depends on how well the various machines, services production
facilities and employees amenities are located in a plant. Plant layout should be the
arrangement of desired machinery and equipment of a plant in such a way which will permit
the easiest flow of materials, at the lesser cost with minimum handling and in processing the
product from the raw materials to the dispatched of the finished product. Increasing global
competition has evolved a manufacturing environment which gleans vast product
configuration, reduced lead times, and increased standards of quality and competitive costs.
In parallel with a rising trend towards globalization, these manufacturing facilities must be
designed to cater for new challenges to survive and grow in the marketplace. The data is to be
collected regarding the spatial arrangements of the various sections of the production layout
and the flow of the raw material for the formulation of the Relationship chart diagram.
Various combinations of the process plant layout can be formulated by considering the
material flow and distance between the departments and the best layout is selected by
checking the efficiency rate which is cross checked by simulation using MATLAB. The
suitable of new plant layout can decrease the distance of material flow, which rises
production.

INTRODUCTION:
Process layout is recommended for batch production. All machines performing similar type of
operations are grouped at one location in the process layout e.g., all lathes, milling machines, etc.
are grouped in the shop will be clustered in like groups. Thus, in process layout the arrangement of
facilities are grouped together according to their functions. A typical process layout is shown in the
following figure. The flow paths of material through the facilities from one functional area to
another vary from product to product. Usually the paths are long and there will be possibility of
backtracking. Process layout is normally used when the production volume is not sufficient to
justify a product layout. Typically, job shops employ process layouts due to the variety of products
manufactured and their low production volumes.

Layout design has been considered as one of the vital areas where business performance
improvement can be realized. Facilities are of crucial importance to organizations since they
usually represent the largest and most expensive assets of an organization. Effective placement of
the facilities is known to have a significant impact upon manufacturing costs, work in process, lead
times and productivity. A good placement of facilities contributes to the overall efficiency of
operations and can reduce up to 50% of the total operating expenses. Its main concern is reducing
cost by maximizing adjacency of highly interacting components of a system or reducing material
handling cost or distance between work stations. If facilities are arranged optimally, manufacturers
can decrease work in process, material handling costs, total production costs and significantly
enhance their systems efficiency. In addition, a good layout brings safe workplace for employees
and thereby increases employee morale, minimize risk of injury to personnel and damage to
property. Plant layout design requires diverse field of knowledge. Among others the application and
use of computers become an advantage. Computer can perform tedious computations and generate
several alternative solutions much more rapidly and effectively than manual procedures. The
computerized layout methods, either construction or improvement-type routines are heuristics.
Construction-type layout routine generates a block layout based on the relationship between
different departments.

NEED OF PROJECT:

Product innovation, production development and shorter and shorter Time to Market are
crucial aspects to face with customers demands and increasing competition on global
 marketplace. Market timing and customer requirements are very important in order to meet the
market window.
A general facility layout problem is concerned with the physical organization/allocation of a
production system. It can be considered belonging to the sense that we have to allocate,M
facilities to M locations (where M represents the problem size). In a facility layout problem
we are going to find a criteria, which maximize/minimize some objectives (quantitative and
qualitative ones like production time, flexibility in volume and variety, allocation space,
product quality, costs etc), in order to find the most efficient arrangement of M indivisible
departments with unequal area requirements within a facility. Therefore, any algorithm
layout approach can be obtained in an amount of time which is bounded by a polynomial in
the size of the problem, and optimal solutions are proposed and, therefore, accepted. We are
thinking of qualitative and quantitative criteria inherent with a multiple objective problem.

LITERATURE SURVEY
SR.NO YEAR OF TITLE OF JOURNAL TYPE OF AUTHOR ANY REMARK
PUBLICATIO INDUSTRY SOFTWARE
N USED

1 2010 TO MODIFY THE FISH YUJIE ET AL - WORK-FLOW

PRESENT PLANT INDUSTRY WAS RE
LAYOUT OF ARRANGE,
CANNED FISH THUS
DISTANCE
DECREASED.

2 2010 PLANT LAYOUT OF STEEL WISITSREE ET AL - ECRS METHOD

BASED ON SLP MANUFA- WAS USED FOR
CTURING IMPROVING
EFFICIENCY

3 2014 IMPROVING - PROF.SHASHI ARENA STRING

EFFICIENCY RATE KIRAN K SOFTWARE DIAGRAM WAS
OF THE PLANT USED.

4 2010 LAYOUT - MANI SHIVHARE MATLAB PSO GIVES A

OPTIMIZATION IN EFFICIENT
FMS SOLN FOR
LOOP LAYOUT.

5 2011 CASE STUDY ON - PROF. MIROSLAW - BY VARYING

ENGG. TO-ORDER LAYOUT WE
COMPANY. CAN INCREASE
THE
PRODUCTIVITY

6 2014 IMPROVING - PROF. RIYAD - IMPROVES

FACILITY LAYOUT HOSSAIN MATERIAL
USING SLP FLOW, COST
AND REDUCED
TRAVEL
TIMING

7 2010 OPTIMAL PLANT - SUKANTO CRAFT DEFINE INITAL

LAYOUT FOR BHATTACHRYA ALGORITHM INPUT BLOCK
PROCESS FOCUED LAYOUT.
SYSTEM

8 2011 ANALYSIS OF PLANT PULLEY PROF. A. WATANA - MODIFIED

LAYOUT DESIGN FACTORY PA LAYOUT FOR
FOR EFFECTIVE CONVENIENT
PRODUCTION WORK FLOW.

9 2013 LAYOUT DESIGN OF - PILIPPO DE - EMPERICAL,SLP

AND LEAN
LOW CAPACITY CARLO
APPROACH WERE
MANUFACTURING COMPARED TO
LINE DESIGN AN
OPTIMAL SOLN.

Project Objectives:
 Collect information regarding process plant layout, lead time and transportation time.

Analyse the current productive of the plant.

Study the various factors affecting the productivity of the plant.

Propose an alternative layout which has an improved productivity by using systematic layout
planning

Obtain the same using simulation in MATLAB and compare the results.

By optimization of process plant layout we achieve a growth in productivity, decrease in cost

per unit and saves precious manufacturing lead time.

The project aims at developing a beneficial plant layout by optimizing the current facility
design by systematic layout planning method and same using simulation in MATLAB.

METHODOLOGY
 FACILITY LAYOUT DEFINITION

For an organization to have an effective and efficient manufacturing unit, it is important that special
attention is given to facility layout. Facility layout is an arrangement of different aspects of
manufacturing in an appropriate manner as to achieve desired production results. Facility layout
considers available space, final product, safety of users and facility and convenience of operations.

An effective facility layout ensures that there is a smooth and steady flow of production material,
equipment and manpower at minimum cost. Facility layout looks at physical allocation of space for
economic activity in the plant. Therefore, main objective of the facility layout planning is to design
effective workflow as to make equipment and workers more productive.

Factors affecting Facility Layout

Facility layout designing and implementation is influenced by various factors. These factors vary
from industry to industry but influence facility layout. These factors are as follows:

The design of the facility layout should consider overall objectives set by the
organization.

Optimum space needs to be allocated for process and technology.

A proper safety measure as to avoid mishaps.

Overall management policies and future direction of the organization

Design of Facility Layout

Principles which drive design of the facility layout need to take into the consideration objective of
facility layout, factors influencing facility layout and constraints of facility layout. These principles are
as follows:

Flexibility: Facility layout should provide flexibility for expansion or modification.

Space Utilization: Optimum space utilization reduces the time in material and people
movement and promotes safety.

Capital: Capital investment should be minimal when finalizing different models of

facility layout.

Types of Facility Layout

There are six types of facility layout, and they are as follows:
 Line Layout

Functional Layout

Fixed Position Layout

Cellular Technology Layout

Combined Layout, and

Computerized Relative Allocation of Facility Technique

SYSTEMATIC LAYOUT PLANNING

The systematic layout planning (SLP) is a tool used to arrange a workplace in a plant by locating
areas with high frequency and logical relationships close to each other. The process permits the
quickest material flow in processing the product at the lowest cost and least amount of handling.

RELATIONSHIP CHART:

A relationship chart is the quantitative matrix containing the level of interaction between pairs of
departments. The more positive the element in the matrix the stronger two departments interact and,
in general, the closer to each other they should be located. The more negative the relationship the
stronger two departments are incompatible with each other and, in general, the farther apart they
should be located.. This diagram is also called an adjacency graph. When the space requirements
for the departments are added to this relationship diagram, then a space relationship diagram has
been constructed
FACILITY UNDER COSIDERATION

Iwai Electronics is one of the leading suppliers of loudspeakers to the Indian entertainment
electronic industry. Established in 1987 as a member of Onida group, primarily to cater to the in
house requirement of loudspeakers for Onida (currently among the top two selling Television
brands in India), Iwai had its own vision of becoming a player of repute in the speaker markets of
India and abroad. Guided by this vision, Iwai has not only been able to carve a niche for itself by
becoming the preferred choice of major consumer electronics conglomerates in India but also has
made a mark in the global market by exporting to countries like USA, Canada, Italy, Finland,
France etc.

Iwai has total commitment towards Quality in all spheres of its activities which has led to the
achievement of consistency and high degree of excellence in all its products and services. Iwai has
been accredited with ISO 9000 certification, which ensures that the quality system in the company
is well maintained. Active involvement of everybody in the organization has been the strong point
for maintaining high quality standards.
 Fig: Autocad drawing of the plant layout

INFRASTRUCTURE

4 production lines capable of producing 800 thousand loudspeakers per month (with
all critical operations automated) spread over 40,000 sq.ft in vasai , near mumbai,
maharashtra state, india

In house voice coil making facility with high temperature materials.

Exclusive dome tweeter manufacturing facility with micro glue dispensing

machines

Capable of producing mobile phone speakers with minor modifications in the layout.

R&D equipped with anechoic chamber and acoustic listening room & mlssa
measurement system.

Simulation softwares such as fine cone & fine motor.

in house painting facility

Manual CORELAP Algorithm:

CORELAP is a construction algorithm to create an activity relationship (REL) diagram or

block layout from a REL chart.

Each department (activity) is represented by a unit square.

Numerical values are assigned to CVs:

V(A) = 10,000, V(O) = 10,

V(E) = 1,000, V(U) = 1,

V(I) = 100, V(X) = -10,000.

For each department, the Total Closeness Rating (TCR) is the sum of the absolute values of
the relationships with other departments.
 Procedure to Select Departments:

1. The first department placed in the layout is the one with the greatest TCR value. I|f a tie

exists, choose the one with more As.

2. If a department has an X relationship with he first one, it is placed last in the layout. If a

tie exists, choose the one with the smallest TCR value.

3. The second department is the one with an A relationship with the first one. If a tie exists,

choose the one with the greatest TCR value.

4. If a department has an X relationship with the second one, it is placed next-to-the-last or

last in the layout. If a tie exists, choose the one with the smallest TCR value.

5. The third department is the one with an A relationship with one of the placed departments.

If a tie exists, choose the one with the greatest TCR value.

6. The procedure continues until all departments have been placed.

Consider the figure on the right. Assume that a department is placed in the middle (position 0).
Then, if another department is placed in position 1, 3, 5 or 7, it is fully adjacent with the first
one. It is placed in position 2, 4, 6 or 8, it is partially adjacent.For each position, Weighted
Placement (WP) is the sum of the numerical values for all pairs of adjacent departments.

The placement of departments is based on the following steps:

1. The first department selected is placed in the middle.

2. The placement of a department is determined by evaluating all possible locations

around the current layout in counterclockwise order beginning at the western edge.

3. The new department is located based on the greatest WP value.

GA-based method for machine layout

A genetic algorithms (GA) is an adaptive search technique which imitates the process of
biological evolution (Goldberg (1989)). A method using genetic algorithms has been
developed to solve the machine layout problem and the programming is done using the
Matlab software with GA toolbox (Chipperfield et. al. (1994)).Two types of layout are
considered, the single-row layout usually associated with the flow-line problems, where parts
have to undergo similar sequence of processes, and the multi-row layout, which is more
appropriate to the job-shop problems where the parts can undergo processes in any sequence.

Since the cost associated with the layout is proportional to the distance travelled by the parts,
the algorithms developed for the multi-row layout has the objective of minimizing the
distance travelled by the parts. In the formulations, cost incurred using the material handling
equipment is assumed to be constant. Hence, the resultant layout will actually minimize the
cost of travelling the distance. The values of the genetic parameters used are given with the
initial population generated at random. The stochastic universal sampling is used to assign the
expected number of offspring to be produced in the next generation for each individuals. A
generation gap (GGAP) of 0.1 is employed, which means that 10 percent of the best
individuals are carried forward to the next generation.

The criterion most often used in the layout problem is to minimize the travel cost of the
parts, with the cost related to the distance travelled. Consequently, the objective is formulated
as minimizing the total travelling distance of parts.

The objective function is given as follows:

N N
Obj min fijcijdij
i 1 j 1

where,

fij=frequency/volume of movement

cij=cost to move one unit load per one distance unit between two machines

dij=distance between machine i and j

Assuming the cost cij remain constant, the objective would be reduced to minimizing the

total distance travelled for the parts.

In certain company, which foresee a possible future expansion of the shop floor, there are
ample space available, creating a situation where the number of possible machine locations
exceed the number of machines. In this situation, dummy machine numbers are used in the
representation. For example, in a case of seven locations and 5 machines, we assign machine
6 and 7 to be dummy machines and machines 1-5 as real machines. The algorithm will find
the locations which minimize the total distance travelled by parts, leaving empty spaces for
locations assigned to the dummy machines. These empty spaces can be used for other uses
 such as storage area in the shop floor. Should the company decide to buy extra machines
these spaces will then be used to put the new machines.

Nonlinear optimization layout technique:

A major shortcoming of most layout algorithms is the simplistic way in which they represent
departments. Most of the algorithms represent departments as equal-sized squares [16] or as
combinations of such squares [2,14]. Some algorithms also place restrictions on the shapes of these
composite departments to make the size of the problem tractable [2]. Because of these restrictions, the
dimensions and positions in which departments can be placed must often be determined by the user
before the algorithm can be implemented. Another problem for improvement of algorithms that allow
different size departments is that the final layout generated may contain irregular shapes that are not
feasible for an actual facility. Both of these problems are overcome in NLT. The formulations of the
models are continuous. This allows departments to be of any area with associated dimensions and to be
placed in any position within the plant. Because of the nature of the nonlinear models in NLT, all
departments are constrained to be rectangular in shape. This results in highly regular facility layout.
Also, NLT incorporates an interchange procedure and user interface that allows the user to move
departments or manipulate the solution models. NLT is based on the use of three related nonlinear
optimization models. There is a representation of a basic nonlinear mathematical model of the facility
layout problem incorporating variable rectangular departments. We then describe our nonlinear
optimization procedure, a modified version of a well-known reliable approach to general nonlinear
problems. This basic model is very useful for solving the difficult problem of fitting rectangular
departments into a given fixed plant, but the solution is highly dependent on the initial location of the
individual departments.

A basic mathematical model of the layout problem

In this section, a model used to approximate the real layout problem is developed. As stated in the
previous section, in NLT the departments are considered to be of fixed area but of variable
dimensioned rectangular shape. The same is true of the facility as a whole. The model NLT is based on
assumes that the total cost per unit distance of transporting items between departments is known. It
also assumes that the same costs are known for each department and the outside wall (for example,
shipping departments have flow to the outside wall). Given these costs, the objective is to minimize the
weighted distances between the departments, and between the departments and the outside wall, where
the weight is the transportation cost times the distance between the departments. In our models, we
measure distances from the centers of the departments. Using this, the mathematical formulation of the
cost of a layout is:

DATA COLLECTED
The block diagram for the current layout is given as follows :
The area assigned for each of the departments of the current layout is given below. Here it is known
to our team that the position of Power room cannot be changed owing to obvious practical
limitations and it is assumed that rest all departments have flexibility in area assigned.

SR DEPARTMENTS AREA
NO
1 WOOD WORK SECTION 60 X 30
2 ADMINISTRATION SECTION 65X 30
3 COMPONENT WINDING 20 X 20
4 POWER ROOM 28 X 30
5 ASSEMBLY LINE 60 X 60
6 QUALITY ASSURANCE 15 X 24
7 SPRAY PAINTING 30 X 30
8 POWDER PAINTING 30 X 10
9 TOOL ROOM 40 X 20
10 PACKING AND F.G. 15 X 15

PRODUCT SEQUENCE:

SPACE RELATIONSHIP DIAGRAM:

Legend
A Rating

E Rating

I Rating

O Rating

U Rating

X Rating

FLOW OF THE RAW MATERIAL

A chart showing the relationships between a set of points. For example, the mileage between
cities (charts shown on many road maps); the flow of material between functional areas of a
plant. Rows and columns have identical titles in a corresponding sequence. Entries in the
chart may represent the distance between centres of departments, number of material
handling trips made between departments in each day, total material movement represented
by weight, cost, quantity etc.

The bottom section has been left blank as it usually mirrors the data in the top half. If
however a one-way system was in use, then the distance A to B might not be the same as the
distance B to A and in the this case the bottom part of the matrix would hold the different
data. When dealing with trips rather than distance, it may be found useful to add totals
columns at the right and bottom edges of the matrix.

0 0 0 0 525 0 0 0 350 0
0 0 0 0 0 0 0 350 0 0
0 350 0 0 795 0 0 525 0 0
0 0 0 0 0 300 0 0 0 0
0 0 525 0 0 0 715 80 0 0
0 0 0 0 0 0 0 0 155 1065
0 0 0 0 0 155 0 0 560 0
0 0 0 0 0 605 0 0 0 450
0 0 350 0 0 110 0 0 0 155
0 0 0 0 0 0 0 0 0 0

SR. PAIR LOAD RANK

NO
1 3-5 1800 1
2 5-10 1800 1
3 6-10 1800 1
4 7-5 1100 2
5 5-6 1000 3
6 1-7 800 4
7 8-5 700 5
8 1-5 600 6
9 1-8 500 7
10 9-1 400 8
11 9-5 200 9
12 3-9 200 9
13 3-6 200 9
14 1-9 50 10
This table gives the information about the frequency of load travelling between the
departments, here, the pair 3-5, 5-10, 6-10 have the highest frequency and hence ranked 1.

TABLE: RANK-WISE ARRANGEMENT OF MATERIAL FLOW

FIG: LAYOUT OF CURRENT LAYOUT

 FIG: LAYOUT OF IMPROVED LAYOUT

REFERENCE

http://elearning.nokomis.in/uploaddocuments/Production%20And
%20Operation%20Mgt/Chp.10%20Plant%20Layout/PPT/Ch10Plant
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http://www.managementguru.net/objectives-and-principles-of-plant-
layout/

http://www.technicaljournalsonline.com/ijaers/VOL%20I/IJAERS
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%202012/174.pdf

http://www.ijmer.com/papers/Vol4_Issue2/Version-1/Q04201141146.pdf

http://www.ijirset.com/upload/2014/april/48_Efficiency.pdf

http://www.ijetae.com/files/Volume6Issue8/IJETAE_0816_16.pdf

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