Volume 5, Issue 10, October – 2020 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Manufacturing Plant LayoutOptimization

Using Simulation
Ashish B. Kanse1, Ashish T. Patil2
1
PG Student, Dept. of Production Engineering, KIT’s College of Engineering (Autonomous), Kolhapur, Maharashtra, India.
2
Associated Professor, Dept. of Production Engineering, KIT’s College of Engineering (Autonomous), Kolhapur, Maharashtra,
India

Abstract:- Today most of industries manufacturing The case study performed at a manufacturing industry
layout can be develop and design using either located in MIDC area of Taswade-(Karad), Satara.
traditionally or new engineering techniques. Most of Theproduction system for simulation using the software,
small and medium scale industries facing the real time FLEXSIM. The performance of the selected process system
problem due to the layout designed in Traditionalway developed through compare the output results of the
which are time consuming and not much easier. simulation system andactual system. Flexsim software
Traditional designed layout facing the number of designed for industrial solution which is developed by
problems like delay in handling of material,product Flexsim simulation Software Production Company
back tracking and bottleneck, machine ideal condition (US).Flexsim is technologically combination of simulation,
etc. FlexSimsoftware is used to develop layout model, computer processing 3D image and datainterpretation [1,3].
simulateandanalyses the machine locations and plant The Flexsim software is easy to use and compatible with
activities.FlexSimsimulation software is used to analyze other software. The basic steps involved inthis software are
the performance of layout byapplying different like creating the model layout, define the layout process,
conditions. Result of each condition shows that setting parameter, compilationand running the model,
productivity is continuous improved.In this study paper analyzing results and theirperformance [8,9].
investigates the effect discrete plant layout on production
capacity and throughput time inmanufacturing process. II. FLEXSIM SOFTWARE

Main function is focuses on a critical plant layout 1. Steps of Modeling and simulation:
and machine bottleneck. Simulation offers economical Flexsim simulation software mostly useful in
alternative to increasing the productivity of all machines manufacturing industries, storage plants and material
in such plant.Finally this paper makes better layout to transport system. Flexsim provides processing data,
get a result which based on modeling and simulation for modeling and optimization the total system.
the manufacturing plant layout.
Modeling and simulation are based on following steps:
Keywords:-Simulation, Layout, FlexSim, Analysis, Model,
Optimization. a) _Plant or System Survey:
Analyze or survey the existing system and then
I. INTRODUCTION determine the different ways of simulation.

At present days, most of the small and medium scale b) _Collection of basic data:
manufacturing industries is highly technically developed The collection of simulation data involved that, data is
and more complicated. Therefore, such industries system is collected as per the simulation targetand data regarding
not properlydeveloped or design with scientific solution.[2]. initial condition of system.
So they are requiredscientific and proper stable technique to
reducecostly mistakes or errors. Simulation is one of the c) Create the Model of system:
technique used for such conditions. Simulationis a virtual Define the model of simulation by usingflow diagram.
technique for analyzing a production system without having Flow diagram includes: 1. Model of temporary entities, 2.
actualexperiment onthe system [1,4]. The simulation model Queuing discipline, 3. Model of service.
guidedfor improvementon machine performance, material
movement and process sequence. Hence, it provides clear d) _Create the simulation model:
picture to the management for taking decision whether the Such process includes choosing a software
investment is useful for it or not. [6,7]. This paper case development and language program design according to
study reviews that, the model ofcurrent production system mathematical model.
are simulate through simulation software Flexsim
andanalyses the production system to define a Productivity
improvement optimization.

IJISRT20OCT570 www.ijisrt.com 861

Volume 5, Issue 10, October – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
e) Validate system Model:  Modeling and simulation of Research plan for military
Validate whether simulation model and Physical operations in urban areas.
system are same. The output results are comparing and
which are similar to each other. 4. Applicable in Logistics & material Supply Chain system:
 Simulation of inventory system computer manufacturing
f) Simulate and running model: environment.
Simulation the model and running the system is  Analysis of bottleneck detection in material supply
important tounderstand the output response with different system.
inputs and different simulation parameter or conditions.  Analysis of passenger flows in an airport.
g) Outputs and analysis result: III. PROBLEM DEFINATION
Finally after software simulation of system, analysis
their output data & adopted best optimize results. After conducting survey it is found that in actual
industrial scenario, shop floor problems are tackled with less
scientific approach. Perfect Components is an industry
involved in manufacturing of various components located at
Karad MIDC. The company is facing with various problems
like complicated plant layout, less space for material
handling, repetitive material backtracking, more component
cycle time/ Considering these difficulties, present project
work aims at tackling above problems in more scientific
manner by taking help of tools like simulation software.
Considering above factors purpose of this paper is
performance improvement through modeling and
simulation.

IV. SCOPE

As per information received from company following

products have more demand per month whose process time
is more. Therefore as per company’s direction we focus the
work with Performance improvement of following products
–

1. Y-Bracket PUNCH and DIE Plate.

2. M-Bracket PUNCH and DIE Plate
3. Frame Die Plate
4. Bush Sleeve
Fig- 1: Steps of Modeling and Simulation
V. EXPERIMENTAL FRAMEWORK
2. Areas of Application:
Here we perform the experimental work by using
1. Applicable in Manufacturing system: Flexsim simulation software. First of all select the 01
 Dynamic modeling of layout in continuous component for experimentation and develop existing layout
manufacturing systems. model in software. Afterward give input data of that
 Simulation analysis in automobile assembly line. component and apply different conditions or iterations on
 Simulation for quality and productivity improvement in that layout. Finally analyses their results.
manufacturing unit.
Component select for Experimental work: M-Bracket
2. Applicable in Construction and Project Management: Die Plates.
 Simulation for drainage operations maintenance system.
 Develop a virtual steel construction model for analysis of Steps of Experimentation:
layout.
 Simulation of the residential material supply chain. A) Survey and Data Collection:
Initially study the existing plant layout of
3. Applicable in Defense Applications: manufacturing unit shown in figure 2. Afterward collect the
machining data by adopting Time study technique.Data
 Analysis of technology effects on human performance
through trade-space development and evaluation of collection include Machining time, Setup time and Machine
technology. to machine distance etc shown in Table 1. In manufacturing
process every operation processing time is the important
 Analyses the Impact of an automatic logistics system.
effectivefactor.Accuratelycalculating time required for each

IJISRT20OCT570 www.ijisrt.com 862

Volume 5, Issue 10, October – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
operation is allows manufacturer to reduce cost, increase For this experimentation work we choose 02
profit and customers satisfaction. components from the manufacturing unit on the basis of
process time is more which is discussed earlier.

Fig- 2: Existing plant Layout

Fig- 3: Process Layout

IJISRT20OCT570 www.ijisrt.com 863

Volume 5, Issue 10, October – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Table-1: Machine-Machine distance data

Table-2: Machining data

B) Simulate Existing layout usingsimulation software:

The existing plant layout is designed by using Flexsim simulation software. It clearly indicates that number of machines,
operators etc.

Give input data like Processing and Setup time, machine distance for each machine which is shown in Table No 1 & 2.

IJISRT20OCT570 www.ijisrt.com 864

Volume 5, Issue 10, October – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Fig- 4: Existing plant layout

Flexsim Results:
After simulating current layout using Flexsim software and applying input parameters,the existing layouts output
production componentsis 17 quantityin week.

Fig- 5: Gantt Chart

Gantt chart shows the different machines conditions for ideal, setup, operator, processing, transport etc.

Object Class Stat Input Stat Output

Source 1 Source 0 124
Hack saw machine Processor 124 23
Milling machine 1 Processor 23 22
Lathe Processor 22 21
VMC Processor 21 20
Grinding Processor 20 19
WEDM Processor 19 18
Hardening Processor 18 17
Inspection Processor 17 17
Sink Source 17 17
Table-3: Result for Week (6days) & considering 2 shift (8Hr/shift)

IJISRT20OCT570 www.ijisrt.com 865

Volume 5, Issue 10, October – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
C) SimulatingLayout for betterproductivity:
The simulated model gives answer of the question i.e. how many Machines are really required in the process to keep
production process working properly. The simulation model should use in the system for analyses influence parameters in whole
process.

Flexsim Simulation Software is used to solve the process problem. Flexsim is new generation simulation software where
models are built directly in 3D.

1] Iteration 1: Arrangement of Machines as per process or Workstation-

We know that extra addition of machine or workstation which automaticallyreflected as a result to improve
productionquantity. Such condition happens when the operators remain idle frequently. So these operators efficiencymay be used
in production so as to improve the productivity of the system.

Fig- 6: Iteration-1

Flexsim Results :

Object Class Stat Input Stat output Idle Processing

Source2 Source 0 1352 0 0
MCM Processor 1352 356 57338.71 1898160
MILLING MCH Processor 356 122 55550.39 1896840
LATHE Processor 122 122 58722.57 1895520
CNC MCH Processor 122 123
GRINDING Processor 123 65 62725.14 1892880
WEDM Processor 65 35 61731.37 1891560
Hardening MCH Processor 35 38 63732.91 1891240
INSPECTION Processor 38 46 63074.97 1894200
Sink16 46 46
Operator1 Sink 0 0 0 0
Operator2 Operator 0 0 2057951 0
Operator3 Operator 0 0 2056992 0
Operator4 Operator 0 0 1945626 0
Operator 0 0 2058557 0
Table-4: Result for Week (6days) & considering 2 shift (8Hr/shift)

IJISRT20OCT570 www.ijisrt.com 866

Volume 5, Issue 10, October – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
After simulating modified layout- Iteration-I using Flexsim software and applying all input parameters, the modified
layouts output production components is 46 quantity in week.

2] Iteration-2:

Fig- 7: Iteration-2

Flexsim Results :

Object Class Stat Input Stat output Idle Processing

Source2 Source 0 1352 0 0
MCM Processor 1352 356 57338.71 1898160
MILLING MCH Processor 356 122 55550.39 1896840
LATHE Processor 122 122 58722.57 1895520
CNC MCH Processor 122 123
GRINDING Processor 123 65 62725.14 1892880
WEDM Processor 65 35 61721.37 1891560
Hardening MCH Processor 35 42 63732.91 1890240
INSPECTION Processor 42 54 63104.97 1895200
Sink16 54 56
Operator1 Sink 0 0 0 0
Operator2 Operator 0 0 2057951 0
Operator3 Operator 0 0 2056992 0
Operator4 Operator 0 0 1945626 0
Operator 0 0 2058557 0
Table-5: Result for Week (6days) & considering 2 shift (8Hr/shift)

After simulating modified layout- Iteration-II using Flexsim software and applying all input parameters, the
modified layouts output production components is 56 quantity in week.

IJISRT20OCT570 www.ijisrt.com 867

Volume 5, Issue 10, October – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Resultstable:

Production
Layout Remarks quantity
Existing Simulation is done as per current layout. 37
1st Instead of adding any new processor, we just rearrange machine 46
Iteration arrange.
nd
2 Iteration Extra WEDM machine is added 56
Table-6: M-Bracket Die plate

Similarly, simulation done on remaining three components as usual applying iterations like rearrangement of machines,
adding extra machines etc. We get the following results-

2. Y-Bracket Die Plate:

Production
Layout Remarks quantity
Existing Simulation is done as per current layout. 32
1st Instead of adding any new processor, we just rearrange machine arrange.
Iteration 37
nd
Extra WEDM machine is added 43
2 Iteration
Table-7: Y-Bracket Die plate

3.Frame Die Plate:

Production
Layout Remarks quantity
Existing Simulation is done as per current layout. 35
1st Instead of adding any new processor, we just rearrange machine arrange. 39
Iteration
nd
Extra WEDM machine is added 46
2 Iteration
Table-8: Frame Die plate

4. Bush Sleeve:

Production
Layout Remarks quantity
Existing Simulation is done as per current layout. 124
1st Instead of adding any new processor, we just rearrange machine arrange.
Iteration 156
nd
2 Iteration Extra Turning machine is added 194
Table-9: Bush Sleeve

Final Result: VI. CONCLUSION

From above results of Four components comparing
with existing layout, it is found that by arrangements of As per the results of 4-componats output we concluded
machines in workstation and extra adding the machine that by analyzing the parameters like manpower, Machine
(where mostly bottleneck problem are identify) the process time, Machine setup time, layout, production rate
production quantity per month is increases means process etc. Simulation software gives the information about effect
time decreases and productivity is increased. of modification of system layout. However it reduce
processing time, increase space, reduce material movement,
a back tracking issue etc. optimizing Flexsim software the
Performance of two iteration is calculated. Every iteration
shows different results.

IJISRT20OCT570 www.ijisrt.com 868

 Volume 5, Issue 10, October – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
It is noticed that 2nd iteration given better productivity
and improve the performance than others. Finally the paper
shows the improved and optimized better machine system
layout with the help of Flexsim software.

REFERENCES

[1]. Victor Emmanuel de Oliveira Gomesa,b, Luis Gonzaga

Trabassoa, A Proposal Simulation Method towards
Continuous Improvement in Discrete Manufacturing,
49th CIRP Conference on Manufacturing Systems
(CIRPCMS 2016)
[2]. N.H. Saad, M.A.A. Farouk, Z. Mohamed and A.R.M.
Sahab, manufacturing plant performance analysis using
simulation technique, 2nd International Conference on
Mechatronics, Kuala Lumpur, Malaysia.
[3]. Jose Arnaldo Barra Montevechi, Amarnath Banerjee,
Federal University of Itajubá, a study on the
management of a discrete event simulation project in a
manufacturing company, 2016 Winter Simulation
Conference.
[4]. Mateusz Kikolski, Identification of production
bottlenecks with the use of Plant Simulation software,
ISMSME 2016 pages: 103-112.
[5]. Dominika LEKS, Aleksander gwiazda, application of
FlexSim for modelling and simulation of the production
process, 2006.
[6]. Akshay D. Wankhade1, Dr. Achal S. Shahare2,
Productivity Improvement by Optimum Utilization of
Plant Layout: A Case Study, Volume: 04 Issue:
06,2017.
[7]. Jianliang Peng, Simulation and Optimization of
Production Logistics System Layout based on
Flexsim,2007.
[8]. Sriram G, Vamsi P, TVSRK Prasad, Modeling and
Analysis of a Manufacturing Plant Using Discrete
Event Simulation, Int. Journal of Engineering Research
and Application, 2248-9622, Vol. 7, Issue 2, ( Part -3)
February 2017, pp.49-54.
[9]. E.Tokoz, Industrial Engineering and Simulation
Experience Using Flexsim Software, Computers in
Education Journal, Volume 8, Issue 4, December 2017.
[10]. Liu Haidong,Workshop Facility Layout Optimization
Design Based on SLP and Flexsim,2005.
[11]. Averill M. Law,Michael G. McComas, simulation of
manufacturing systems, 1997 Winter Simulation
Conference, U.S.A.

IJISRT20OCT570 www.ijisrt.com 869