Rearrangement of Machines on Shop Floor using … of Machines on Shop Floor using Genetic ......

SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015

ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 56

Rearrangement of Machines on Shop Floor using Genetic

Algorithm Vikram Singh

a, Sanjeev Verma

b

a, Student, Department of Mechanical Engineering

PCET, India

b, A.P, Department of Mechanical Engineering

PCET, India.

Abstract: The objective of this paper is to reduce

movement distance in order to increase the

productivity and decrease the cost of component and

this can be done if we decrease the characteristics of

layout using Genetic Algorithm. This project is

conducted at Unitech Machines Limited.

Manufacturing company located in Saharanpur. The

major problem faced by the company is high

bottleneck. The one more problem that also occurred

in the Existing layout is the high movement distance

by going through by pass of machine is also removed

by designing the new shortest path from one machine

to another machine in according to the sequence of

operations. In this we have installed a PAM machine

in the shop floor that reduces the movement time and

movement distance from company to vendor and then

return.With the implementation of proposed layout

the floor space is utilized efficiently and properly and

with the pathways, every machine is accessible

through overhead crane. Genetic Algorithm programs

include a number of parameters including the

probabilities of crossover and mutation, the

population size and the number of generations. A full

factorial experiment was performed to identify the

best configuration. The number of generations was

the only statistically significant factor. When the

layout was treated as a green-field problem the total

rectilinear distance travelled was reduced by 70% and

the population size, the number of generations and

the probability of crossover were statistically

significant. The results were compared with the

Company‟s layout and the best layout that could be

generated randomly. With better placement of

machines and path ways, plant is capable of taking

maximum production at minimum labour cost. The

difference between Existing and new material

distance shows reduction in the movement distance

of the components. Material handling distance among

the machines is reduced by 70.84%.

1. INTRODUCTION

Plant layout planning refers to the arrangement of

physical facilities such as machines, equipment,

tools, furniture etc. in such a manner so as to have

quickest flow of material at the lowest cost and with

the least amount of handling in processing the

product from the receipt of raw material to

the delivery of the final.Facility layout problems

(FLPs) concerning space layout optimization have

been investigated in depth by researchers in many

fields, such as industrial engineering, management

science, and architecture. Layout design

investigations have been helped by recent advances

in computing science and also by increased

understanding of the methods used for developing

mathematical models. The FLP has applications in

both manufacturing and the service industry.

There are mainly four types of plant layout

Product or line layout

Process or functional layout

Fixed position or location layout

Combined or group layout

COMPANY PROFILE:-

Unitech Machines Limited incorporated in the year

1986 is a leading organization specializing in the

field of Turnkey Installation throughout the country

and are well equipped with a team of dedicated

engineers in the field of design, procurement,

project management & erection and commissioning

of systems. UML undertake complete design,

engineering, fabrication, supply, installation,

testing commissioning of utility piping system,

firefighting system, fire detection and alarm

system, and tank ages.

2. Literature

Jin-Ling Lin a, Bobbie Foote et al. [1996] The

problem of assigning positions to unequal fixed size

and shape departments within a given plant area has

prompted numerous research efforts in recent years.

Most of the published papers discuss techniques that

place departments in such a way that the local cost of

material flow between departments is minimized.

Many of these techniques assume that there exists at

least one-feasible layout.

M. Hasan Imam and Mustahsan Miret al. [1998]

proposed an analytical technique to optimize the

layout of building-blocks of unequal areas in a

continuous plane. A construction-cum-improvement

documents/www.internationaljournalssrg.org



type algorithm is introduced in which the optimum

position of each block was determined by piece wise

one-dimensional search on the boundary formed by

the cluster of previously placed blocks. The search

process was dynamic so that all boundary blocks

were continually moved to their optimum positions

until no more improvement was possible. The

technique was implemented in a computer program

which was fully automated and did not require any

user interaction to obtain the optimal layout.

C. M. L. Castell, R. Lakshmanan,et al. [1998] The

layout of chemical facilities is an activity that is

largely carried out by the human designer. Few

methods exist for optimizing layout. Difficulties in

formulating the problem as a mathematical program

stem fromnon- convexities as well as from non-

differentiable cost functions.

Christian Hicks [2006] proposed a Genetic

Algorithm optimisation method that had been

developed which could be applied to a set of

manufacturing cells or to an entire manufacturing

facility. The approach could be used for either green

field or brown field layout problems. The model was

tested using a large data set from a collaborating

capital goods company. Genetic Algorithm programs

include a number of parameters including the

probabilities of crossover and mutation, the

population size and the number of generations.

Lou Y. Liang and Wen C. Chao [2008] proposed

that the facility layout problem was concerned with

finding the optimal facility arrangement in the

existing layout. From many artificial intelligence

searching methods, the tabu search was widely

applied to the optimization problems. In this paper,

the efficient strategies of tabu search algorithm had

been developed to improve the layout in the facility

layout problem. In order to improve the layout

results, the strategies in the different intensification

and diversification procedures were proposed in this

study.

Wei Xie et al. [2008] proposed a continuous facility

layout (CFL) models to address the limitations by

modelling facilities as geometric entities and

searching for an optimal two-dimensional packing.

However, solving these proposed models becomes

dramatically harder: finding optimal layouts for these

models was beyond reach of current optimization

techniques, except for tiny instances. In this paper,

they presented several important theoretical results.

Christian Díaz-Ovalle et al. [2010] proposed a new

approach to determine the optimal distribution of

process facilities was presented in this paper. The

formulation considers a set of facilities already

installed in a given land and a new set of facilities to

be accommodated within the same land. In addition,

it was considered that a set of facilities either

installed or to be laid out presents the possibility of

toxic release. Based on previous analysis, the worst-

case scenario implied calm wind and stable

atmospheric condition. Since these conditions tend to

exist during several days of the year, the proposed

model was formulated assuming these deterministic

values for wind and atmospheric conditions.

IrajMahdavia et al. [2013] proposed a new

integrated mathematical model considering cell

formation and cell layout simultaneously. The goal of

their model was to group similar parts and

corresponding different machines in same cells.

Machines sequence in each cell and cell positions is

also specified in the system.

3. PROBLEM FORMULATION AND

OBJECTIVE

3.1 EXISTING LAYOUT

Certain information about materials and the process

of manufacturing which has been selected is

important in developing a layout. In a layout problem

involving a product already in production,

information on the process may be obtained from the

records of the appropriate department within the

plant. When a new product is to be made in the

proposed layout, such information must still be

obtained, but it will probably have to be developed

by layout man [9]. The existing layout of Press Shop

of UM Ltd. is shown in Figure 3.1 having the

dimension of length 90 feet and breadth 64 feet. In

this length is along the west-east direction. Thus the

total area of the shop floor is 5760 square feet and the

total space occupied by the machines is nearly 807

square feet. This is the very small utilization of

available space and there is a maximum movement of

material like movement of raw or finished product

from one machine to another machine. In this layout

the total available machines is nearly 28 with store

room facility. These machines with their dimensions

are shown in the given table 3.1 and the arrangement

is shown in the figure 3.1 (Exiting Layout of Press

Shop). From the study of this layout we find that

there will be need to utilise the available space.

Utilisation of this space can be done by designing

good layout and minimising the movement time and

movement distance.




Figure 3.1: Existing Layout of Press Shop




Table 3.1 : Machines available on Shop floor

SERIAL NO. MACHINESNAME MACHINES

CODE

DIMENSIONS(L×B)

FEET

1 Hydraulic Press P1 3×3




5 Radial Drilling DM 6×6

6 Mechanical Shear MSM 5×5

7 Break Press BP 5×5

8 Mechanical Break Press MBP 7×5

9 NC-Break Press NBP 7×5

10 Shear Press SP 5×5

11 Mechanical Shear Press MSP 7×5

12 NC-Shear Press NSP 7×5

13 Muller Machine MM 6×3

14 Die Rack DR1 5×3

15 Die Rack DR2 5×3

16 Panel Rolling PR 15×4

17 Cold Section Rolling SR1 15×4

18 Cold Section Rolling SR2 15×4

19 Pallet PA1 15×4

20 Pallet PA2 15×4

21 Pallet PA3 15×4

22 Power Press PP1 4×4



25 Store S1 4×4

26 Store S2 4×4

27 Store S3 4×4

28 Store S4 4×4

TOTAL AREA OCCUPIED (square feet) 807



ISSN: 2348 – 8360 www.internationaljournalssrg.org 9

Table 3.2:Operation Chart of Press Shop

From the available data of these tables we find that

there will be a need to reduce movement time and

movement distance in order to increase the

productivity and decrease the cost of component and




this can be done if we decrease of the characteristics

for designing layout.

This ratio indicates the percentage of the amount of

rectangular-shape machines compared with the

number of square-shape machines as in equation (1).

It relates to P/D point depending on the orientation.

Apply Genetic Algorithm (GA) to examine machine

selection rules proposed inthis work for minimizing

the total handling distance of material flows between

machines and alsothe manufacturing cost of product.

4. Methodology

4.1 PROGRAMMING OF GENETIC

ALGORITHM

Apply Genetic Algorithm (GA) to examine machine

selection rules proposed in this work for minimizing

the total handling distance of material flows between

machines; and also the manufacturing cost of

product.

ii) Investigate the influence of rectangular-to-

square (R/S) ratios associated with machine

dimension on the efficiency of layout design.

Designing the rotatable machine layout followed by

Genetic Algorithm process for solving MLD problem

and its pseudo-code. The experimental results are

presented in next section. Finally, the conclusions are

drawn in the last section.

4.1.1 Layout design of rotatable rectangular

machines

Design task of rectangular machine layout is

concerned with the placement of machines into a

limited shop floor area (Length: FL and width: Fw)

having gap (G) between machines. In multiple-row

environment, predefined machines are arranged row

by row, from left to right, starting at the first row

(R1) and respecting FL and the gap (G).). The design

usually constrains by.

M is a number of machines, i and j are machine

sequences (i and j = 1, 2, 3,…, M), fijis frequency of

material flow between machines i and j, dijis the

distance between machines i and j (i ≠ j).

5. RESULTS AND DISCUSSION

5.1 LAYOUT ALTERNATIVE (PROPOSED)

the new layout of press shop of UM Ltd. having the

same dimension that in Existing layout also having

the same area but there is some change in the

movement path of material and some change in the

layout are shown in given figure 3.1 and here the area

of movement path is 2014 square feet. And the area

occupied by the machines is 1043 square feet. Then

the total area used by machines and movement path is

3057 square feet and total available area in shop is

5760 square feet and the remaining area is used as the

allowance given around the machines and working

persons in order to achieve good working

environment. Here from the figure 3.3 the yellow

block shows the movement path of material and tools

with the help of overhead crane. Figure 5.1 shows the

new layout of press shop helps in removing the

bottleneck from the section rolling machine by

adding a new cold rolling SR3 machine. By adding

this machine at the given location shown in the layout

improves the production and minimise the waiting

time. The one another problem occurred with

Existing layout is cutting of more than 8 mm. thick

sheet is also removed in this new layout by installing

the required PAM machine. This machine can be able

to cut or bend more than 8 mm thick sheet. Thus by

installation of PAM machine in this shop reduces the

movement time and movement distance from

company to vendor and then return. The one more

problem that also occurred in the Existing layout is

the high movement distance by going through by

pass of machine is also removed by designing the

new shortest path from one machine to another

machine in according to the sequence of operations.

By minimising the movement distance the movement

time is also reduced that will help in reducing the

cost of product and increasing the production.




Figure 5.1 Alternative Layout




Table 5.1: Present Machines Available with their occupied space on shop floor

SERIAL NO. MACHINE

NAME

MACHINE CODE DIMENSION(L×B)

1 Muller Machine MM 6×3

2 Die Rack DR1 5×3

3 Die Rack DR2 5×3




7 Radial Drilling Machine DM 6×6

8 Plasma Arc Machine PAM 12×6

9 Mechanical Shear Machine MSM 5×5

10 Hydraulic Brake Press HBP 7×5

11 NC-Brake Press NBP 7×5

12 Hydraulic Shear Press HSP 7×5

13 NC-Shear Press NSP 7×5

14 Store 1 S1 4×9

15 Store 2 S2 4×9

16 Section Rolling(cold) SR1 15×4

17 Section Rolling(cold) SR2 15×4

18 Section Rolling(hot) SR3 15×4

19 Panel Rolling PR 15×4

20 Pallet PA1 15×4

21 Pallet PA2 15×4

22 Pallet PA3 15×4

23 Pallet PA4 15×4




27 Power Shear PS 4×4

28 Mechanical Press MP1 4×4

29 Mechanical Press MP2 4×4

30 Store S3 4×9

31 Store S4 4×9

TOTAL AREA OCCUPIED (square feet) 1028




Figure 5.2 Flow of Component Special and Regular Hat On Proposed Layout




5.3 COMPARISON OF MATERIAL

MOVEMENT

The comparative chart of material movement. In this

chart we compare the separate and total material

movement of all the components. The difference

between Exiting and new material distance shows

reduction in the movement distance of the

components. Thus after comparing the entire

components we have saved total 704 feet movement

distance. This movement distance saved is in moving

the one batch of the components. In one batch we can

take maximum of one coach components because of

the capacity of overhead crane. This crane is

designed only to take the component of one coach

because of some safety reason.

The given figures shows the comparative graph of

various components drawn on Existing layout and

proposed layout

Figure 5.3 Flow Graph of Component Special Hat




Figure 5.4 Flow Graph of Component Regular Hat

Figure 5.5 Flow Graph of Component Side Channel




i)

Figure 5.6 Flow Graph of Component Rain Gutter

Figure 5.7 Flow Graph of Component Floor Channel




Figure 5.8 Flow Graph of Component Section Panel

Table 5.2: Comparative Movement Chart

Sr. No. COMPONENT MOVEMENT(FEET) DISTANCE

SAVING

Existing Proposed

1 Special Hat 150 008 142

2 Regular Hat 160 008 152

3 U-Section 010 008 002

4 Side Channel 265 116 149

5 Rain Gutter 015 10 005

6 Floor Channel 262 140 122

7 Section Panel 167 010 157

Total Saving in the movement of material 729

.




Table 5.3 Results of Comparisons

Sr. No. Saving Factor Saving per batch Saving per batch (%)

1 Travel distance(feet) 729 70.84

2 Time(minute) 3:30 10.29

3 Cost(Rs.) 292 70.87

CONCLUSIONS:

With the implementation of proposed layout

the floor space is utilized efficiently and properly and

with the

pathways, every machine is accessible

through overhead crane.

Material handling distance among the

machines is minimum.

With better placement of machines and path

ways, plant is capable of taking maximum

production at minimum labour cost.

REFERENCES

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For Irregularly-Shaped Machines With Transportation Path

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of Process Plant Layout Using Genetic

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Rearrangement of Machines on Shop Floor using … of Machines on Shop Floor using Genetic ......

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