Plant Layout Evaluation

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Presentation transcript:

Plant Layout Evaluation

10 Evalution (1) Selection and implementation best layout cost of installation + operating cost compare future costs for both the new and the old layout other considerations selling the layout assess and reduce resistance anticipate amount of resistance for each alternative

10 Evalution (2) Causes of resistance: Minimize resistance by inertia uncertainty loss of job content … Minimize resistance by participation stages

Implementation Installation Periodic checks after installation planning Periodic checks after installation

Systematic Layout Planning 0 Data gathering 10 Evaluation Analysis Search Selection 4 Space requirements 5 Space available 6 Space relationship diagram 1 Flow 2 Activities 3 Relationship diagram 7 Reasons to modify 8 Restrictions 9 Layout alternatives

Systematic Layout Planning 0 Data gathering 10 Evaluation Analysis Search Selection 4 Space requirements 5 Space available 6a Space relationship diagram 1 Flow 2 Activities 3 Relationship diagram 7 Reasons to modify 8 Restrictions 9 Layout alternatives 6b Analytical analyses

Automatic Guided Vehicles (AGV’s) Unmanned vehicle for in-plant transportation on manufacturing and assembly areas Two types of guidance free ranging dead reckoning + lasers or transponders path restricted induction wires in the floor AGV  fork lift truck with RF-communication

Design and operational control of an AGV system track layout number of AGVs operational control Traffic control: zones max. throughput capacity

Track layout infrastructure location of pick-up and drop-off stations buffer sizes congestion/blocking tandem configuration

Determination of number of AGVs 5 x 6 x 4 x LP-problem (i.e. a classical TP)

Operational transportation control Job control (routing and scheduling of transportation tasks) Traffic control Traffic rules Goal: minimize empty travel + waiting time Single load: Performance indicators: - Throughput - Throughput times

Operational control production control  transportation control flow shop job shop centralized control all tasks are concurrently considered or decentralized control FEFS: AGV looks for work (suited for tandem configuration) think-ahead combine tasks to routes or no think-ahead

Relations between the issues

Combination 1 Separated/no think-ahead centralized control on-line priority rules: transportation task assignment tasks wait, or idle vehicle assignment idle vehicles wait Ad 1: push/pull (JIT), e.g. FCFS, MOQRS Push  sometimes “shop locking” Ad 2: NV, LIV

Combination 3 Separated/think-ahead (1) Centralized control a. without time windows Only routing Minimize empty travel time by simulated annealing: 2 options: determine optimal route each time a new task arrives problem: a task may stay at the end of the route Periodic control time horizon (length?)

Combination 3 Separated/think-ahead (2) Centralized control b. with time horizons Simulated annealing machine 1 machine 2 machine 3 loaded trip empty trip

Combination 4 Integrated/think-ahead AGV’s ~ parallel machines empty travel time ~ change-over time transportation time ~ machine time Shop-floor scheduling

Basic concept