Track: Lean

Abstract

Plant layout and design plays a very important role in the design and engineering phases of any industrial facility. Implementation of lean manufacturing principles and believing in continuous improvement are the tools which help industries to sustain global competition. With the escalation in population, the demand for technology is increased more than ever. This leads to the steady increase in production rates of existing models and even introduction of new product models. These factors often results in “layout modification” of manufacturing industries. This study  simplifies the application of systematic layout planning in the development of new layout. It is a technique used for layout development and material flow improvement. The results include five possible rearrangements of production departments. These layout alternatives are evaluated on basis of improved accessibility and material flow efficiency criteria. Hence in order to study and modify a service sector plant (Zonal Workshop APSRTC Vizianagaram) has been chosen to carry out the project further.

              The  main aim of study is to understand operations performed with respect to time taken in their assigned station in order to reduce the overall transportation time by either combining different operations , removing  machining errors or removing idle stations to reduce the cycle time as well as man power involved. The process improvement activity achievement not only depends on the redesign of the layout but also involves operators’ utilization and their position arrangement. The relation between them was computed by taking the man power occupancy on machinery calculations, minimized idling time and changing the work sequence. This study adopts a multifarious approach combining manpower occupancy on machinery, lean manufacturing line balancing and layout improvement in productivity on the product. A comprehensive methodology is adapted to systematically to investigate and analyzes the current situation of wastes elimination of the manufacturing firms. This is followed by waste identification (MUDA) and elimination of unnecessary resources to balance the line and optimize the cycle time and promote lean thinking.