Production-time evaluation technique for small manufacturing plants

Abstract

Small manufacturing plants usually experience challenges of inefficiency and low production yields. These problems have previously been addressed using methods to redesign plant layouts and reduce distance between workstations. Furthermore, assessment techniques like the machine-distance matrix method have then been required to evaluate layout performance. However, these assessments that rely only on distance evaluation are severely limited. In this paper, a new model called Production-time evaluation is presented for evaluating production layout efficiency. It involves computing the estimated time for production at workstations, time for movement between workstations and number of units of a product manufactured. It is then applied on a case study in small furniture plant. The existing layout of the plant was extracted and the production processes for its three products were outlined. A new layout was designed and both layouts were compared using the Production-time methodology, revealing improvements in reduced production time and increased daily production capacity by up to 37% for a product.

Keywords

• plant layout
• optimization
• machine distance matrix technique
• production
• mathematical modelling