LAYOUT OPTIMIZATION USING MANUFACTURING SYSTEMS SIMULATION SOFTWARE (VIP-PLANOPT) Presented by Perumalsamy

LAYOUT OPTIMIZATION  Layout Optimization is one of the top issues, for industrial facility planners in USA and around the world. It has profound effects on organizational productivity and profitability  Optimizing the Layout of a Plant can improve productivity, safety and quality of Products. Unnecessary efforts of materials handling can be avoided when the Plant Layout is optimized. This is valid for

1.Distances Material has to move 2.Distances Equipment has to move 3.Distances Operators have to move 4.Types of Handling Equipment needed PRELIMINARY PROCEDURE: 1. Study the given layout to be optimized 2. Measure the length and width of all the machine in the shop floor to be optimized 3. Study the boundary shape of the shop floor and measure the overall dimension of the layout

PROCEDURE Open VIP-PLANOPT software Click on File New Click on Boundary Shape tab under optimization constraints in Optimization parameters as shown in Fig 1

In the Boundary Shape constraint window that appears, choose the required shape type of the Layout. By choosing the composite shape, it is possible to sketch the required complex shape of the layout or by choosing the simple rectangle, you can enter the dimension of the layout in the box that appears below (Fig) Then click on Exit.

Choose the type of module either hard or soft under module type Hard modules have user-specified dimensions. The dimensions of such modules are not modified during optimization. A module with variable aspect ratio but of constant area is called soft or flexible module. The user has to specify the area of a soft module with the upper and bounds on its aspect ratio. The user may also specify a set of permissible values of aspect ratios. The aspect ratios of all such modules are varied during optimization. Give the length and width of the first machine as input to the PLANOPT software under dimensions option. For the next machine, click on create option and enter the dimensions. The box below shows the no of machines, its dimensions and its aspect ratio (Unit for dimensions should be same everywhere)

Click on Module Padding tab under optimization constraints in Optimization parameters. In the Module Padding constraint window that appears, enter the Top, Bottom, Left and Right spacing. Then click on Exit.(Only hard modules that have fixed dimensions may be padded) Select the orientation of the machine either fixed or may flip Fixed orientation means that machine orientation cannot be changed. May Flip means, the machine can be oriented to any direction to be optimized Select the position of the machine either Movable or anchored A module whose position (location) is fixed and is not allowed to change during optimization is called an “anchored” module. PLANOPT produces optimal layouts with anchored modules located strictly at the user-specified position.

Pick-up & Drop-off Points Click PD Point as shown in figure PLANOPT allows the user to specify pick-up and drop-off points anywhere inside or on the boundary of the modules. Relative coordinates with respect to the lower left corner of the module are used to specify the pick-up and drop-off points. For example, if the pick-up and drop-off points for a module have to be as shown in Fig, the user will specify the pick-up point coordinates as xP = 3, yP = 1 or (3,1) measured from the lower left corner of the module. Similarly the coordinates of the drop-off point will be specified as xD = 0, yD = 2 or (0,2)

Click on show all option as shown in fig below

Flow Matrix 1. The flow matrix gives the “flow” of material, equipment or personnel between all pairs of modules. An element of this matrix, denoted by fij, is the flow between any two modules i and j. It is expressed in number of unit loads moved per unit time between the two modules. 2. A unit load is defined as the unit to be moved or handled at one time. 3. The unit load includes the container, carrier, or support that will be used to move materials. PLANOPT allows the flow matrix to be either symmetric or non-symmetric. In some applications, this matrix is also referred to as the "connectivity matrix”.

Unit Cost Matrix The matrix representing the cost of transporting a “unit load” (as defined above) per unit distance between all pairs of modules is called “unit cost matrix”. An element of this matrix, denoted by uij, is defined as the cost of transporting a unit load of material per unit distance from module i to module j. Cost Matrix An element of this matrix, denoted by aij, represents the total cost of flow per unit distance between any two modules i and j. In other words aij = fij * uij. PLANOPT allows the cost matrix to be either symmetric or non-symmetric. PLANOPT gives the user the option of specifying either directly the values of aij or instead the values of fij and uij separately.

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