OPTIMIZATION OF PLANT LAYOUT ANJUMAN-I-ISLAM’S KALSEKAR TECHNICAL CAMPUS, NEW PANVEL OPTIMIZATION OF PLANT LAYOUT -AT OTOKLIN GLOBAL BUSINESS LIMITED Partial Fulfilment of Dissertation work by- MIRZA ANEES 14DME154 SHAIKH ASIF 14DME162 SHAIKH BURHAN 14DME164 SHAIKH FAISAL 14DME166 UNDER THE GUIDANCE OF : PROF. SAAD SHAIKH DEPARTMENT OF MECHANICAL ENGINEERING

OVERVIEW Introduction Problem definition Objective Review of Literature Methodology Predicted Analysing of the work Expected Outcome Implementation of SLP References

INTRODUCTION Plant layout is the most effective physical arrangement, either existing or in plans of industrial facilities. Optimization of a plant layout is a methodology of making system as fully perfect, functional, or effective as possible. OTOKLIN GLOBAL BUSINESS LIMITED Filters making company Year of establishment : 2003 Products: Air filters, Coolant filters, Sand filters, Strainer, etc. Major Vendors: L&T, TATA Groups, Reliance.

The plant suffers from poor utilization of workspace, poor material handling and safety hazards. Also placement of raw material and in process material hinders manufacturing process. So, our aim is to optimize the plant layout for efficient production system and select suitable material handling system, which in turn will also increase productivity of plant.

GENESIS OF PROBLEM Improper utilization of workspace area. Poor placement of machining equipment. Problems in material handling causing unnecessary increase in production time and cost. Several injuries of labours due to improper precautionary measures.

CURRENT SCENARIO

OBJECTIVES To study the current flow pattern and relation of overall plant layout. To develop a new plant layout. To select appropriate storage system.

REVIEW OF LITERATURE Sr.no Paper name Year Authors Purpose Conclusion 1 Efficiency Improvement of a Plant Layout 2014 Vivekanand s Gogi, Rohith Shashi Kiran , Suhail M Shaikh To study and improve the current plant layout and are analysed & designed by using string diagram. Instead of criterion of minimizing total distance travelled, it is suitable to minimize the total distance of the material travelled. 2 Production Layout Optimization for Small and Medium Scale Food Industry 2015 Yosra Ojaghia, Alireza Khademia, Noordin Mohd Yusof To reduce the costs of their product. Use of SLP and GBT has resulted in six different layouts involving thirteen departments. (ER) method helped in calculation of efficiency for the different layouts generated

A facility allocation technique of the layout Sr.no Paper name Year Authors Purpose Conclusion 3 Analysis and Optimization of Plant Layout using Relative Allocation of Facilities Technique 2013 Bobby John, Jubin James, R. Mahesh Rengaraj A facility allocation technique of the layout The existing layout checked using Computerized Relative Allocation of Facilities Technique (CRAFT) and an improved new layout was proposed. 4 Improvement in Plant Layout Using Material Handling 2012 Amrita Kirtane, Nagendra Sohani Produce complete coupling by using the same Mfg. facilities without major changes. Existing layouts have been modified by using Travel Chart Technique analysis and considering material handling cost as the criterion. 5. Optimization of Plant Layout Using SLP Method 2016 Shubham Barnwal, Prasad Dharmadhikari To develop a new layout based on the SLP pattern theory The proposed model based on SLP was found to be effective, production rate increased, the production time was reduced and total distance travelled by material also reduced.

METHODOLOGY Levels of plant layout design: 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. Levels of plant layout design: Site layout: shows how the building should be located in a proper way. Block layout: shows the sizes of departments in the buildings. Detailed layout: shows the arrangements of equipment and workstations in the departments. Workstation layout: shows the locations of every part of the workstation.

PREDICTED ANALYSING OF THE WORK After knowing the relationships between flow of raw materials and in process inventories with activities (manufacturing processes and material handling) it becomes necessary to draw plant layout. In order to select best suitable layout we have to draw different layout with different possibilities. Some of the software used in drawing plant layout are: SmartDraw's facility planning software AutoCAD Plant 3D  Open Factory 3D.

EXPECTED OUTCOME Proper arrangement of machine tools according to the sequence of operations to be followed. Less material handling. Increased production rate.

STORAGE OF RAW MATERIAL FLOW OF MATERIAL STORAGE OF RAW MATERIAL PROCUREMENT & MARKING & GAS CUTTING ROLLING WELDING a. Arc Welding b. spot welding PAINTING TESTING ASSEMBLY & FITTING DISPATCH

ACTIVITY RELATIONSHIP CHART An Activity relationship Chart is a Tabular means of displaying the closeness rating among all pairs of activities or departments. Generally, in any manufacturing firm various activities are related to each others either by flow of material, handling possibilities or constraints in layout. The activity relationship chart of our plant layout is as shown with the possible ratings and reasons for their closeness.

Rating Type of Relationship A Absolutely Necessary E Especially Important I Important O Ordinary U Un-important X Undesired Rating Reasons 1 Flow of material 2 Ease of supervision 3 Convenience 4 Production Control 5 Injury Chances/Safety 6 Material Control

SPACE AVAILABLE Perhaps the most difficult step in facilities planning is the determination of the amount of space required in the facility. Space requirement should be determined: For individual work stations For department requirement The total area available in the plant is 24 x 34 (840) m2 .

Types of Products a. Small size Products c. Big size Products b. Medium size Products

PROPOSED STORAGE SYSTEM Depending upon the weight to be carried by storage device and to decrease the space, we proposed double sided cantilever racking system. Taking a survey through various websites, we found rack according to our dimensions and load carrying capacity on ‘GLOBAL INDUSTRIAL’ which offers various sub-parts to be assembled. Such a rack cost Rs. 1,90,000/- approximately.

SPACE RELATIONSHIP DIAGRAM It is derived from activity relationships. It represents the relation between available space and degree of closeness to be kept between various departments. Absolutely Necessary Especially Important Important

PROPOSED LAYOUT - 01 Sr.No. Sections Area (m2) 1. Storage (For pipes) 7 x 2 2. Machining (Gas Cutting) 7 x 2+7 x 2 3. Rolling 4.5 x 9 4. Fabrication 2.5 x 4.9 5. Fitting 3 x 3 6. Temporary Storage (WIP) 5 x 4 7. Testing 2 x 2 8. Painting 3 x 2 9. Dispatch 5 x 5 10. Office 4 x 8 11. Inventory 6 x 9 12. Scrap 4 x 2

Improvements Proposal of Racks Previous proposal New proposal

PROPOSED LAYOUT - 02

Costing of Rack Loading and unloading of material is easy as compared to previous rack. Each individual drawer or shelf can be accessed independently from the others, and offers very safe and secure storage. Cost when new-$14,000 approx. 9,70,000 INR each.

Sizes of VAGs ø3.7m 2.5m 3-Decker Cost-*** 2-Decker Cost-10 Lacs/piece

EXPECTED OUTCOME A. For large size product: (duration - 45 days) Current capacity for large size product : 04 VAGs Total capacity with proposed layout : 05 VAGs Relative increase in productivity: Increase in capacity current capacity =1/4*100 =25%

B. For small size products: Product of size 0.5m x 0.4m x 0.3m Maximum no. of products: 250 (duration : 60 days) Currently, no. of products produced simultaneously: 4 in a batch. Thus, requires 63 batches. With proposed layout, no. of product expected : 5 in a batch. Requires 50 batches. Total increase in productivity: (63-50)/63 =0.2063 =20.63%

Cost of Products

Expected profit to be earn: For large product: Manufacturing time for a product: 45days Annual days: 300 working days Increase in no. of products annually: 6.66= 6 products Approximate cost of product: 10lacs/product Profits earned: 6 x 10= 60,00,000 INR For small products: Currently, no. of product manufactured: 1,250 per annum Expected no. of product to be manufactured: 1,560 per annum Approximate cost of product: 3000rs/product Profits earned: (1560-1250) x 3000 = 9,30,000 INR TOTAL PROFIT TO BE EARNED: 69,30,000 INR p.a.

References Subodh B Patil1, S.S.Kuber., “Productivity improvement in plant by using systematic layout planning (SLP) - a case study of medium scale industry”, IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 Amrita Kirtane, Nagendra Sohani, “Improvement in Plant Layout Using Material handling Technique”, International Journal of Science and Research (IJSR) ISSN (Online): 2319-7064 Shubham Barnwal, Prasad Dharmadhikari, “Optimization of Plant Layout Using SLP method”, International Journal of Innovative Research in Science, Engineering and Technology-Vol. 5, Issue 3, March 2016 Chandra Shekhar Tak, Mr.Lalit Yadav, “Improvement in Layout Design using SLP of a small size manufacturing unit: A case study”, IOSR Journal of Engineering (IOSRJEN) - Volume 2, Issue 10 (October 2012), PP 01-07 http://www.globalindustrial.com/p/storage/bulk-rack/cantilever/cantilever-rack- double-sided-upright-36 http://www.eurostorage-systems.co.uk/storage-profiles/roll-out-rack.php

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