Research method on facility layout design and material handling

Research proposal on Facility layout design and material handling of

Manufacturing Industries

Submitted by….… Yonas Tegegn ---1403186

Firaol jonse-------1401261
Yonas biede-------1403088

Advisor……. MR. YONAS.H

Debre Berhan University

School of Engineering
Department of Industrial Engineering

Submission date---------

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Research method on facility layout design and material handling
Table of contents
Content……………………………………………………………………………………………….
Abstract……………………………………………………………………………
1. Introduction/Background………………………………………………………..
2. Problem statement………………………………………………………………
3. Literature review………………………………………………………………
4. Objective of thesis…………………………………………………………
4.1. General Objective……………………………………………
4.2. specific Objectives……………………………………………..
5.Methodology of the study………………………………………………………
5.1.Design of the study……………………………………………………
5.2. Method of data collection…………………………………………..
6. Expected out put……………………………………………………………..
7. Time frame……………………………………………………………………….
8. Reference………………………………………………………………………………………….

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 Research method on facility layout design and material handling

Abstract
Facilities layout and material handling are critical components in the design and operation of
industrial facilities, significantly influencing operational efficiency, productivity, and overall
organizational performance. The layout of a facility refers to the arrangement of physical
resources, including machinery, equipment, storage areas, and workstations, within a defined
space. An effective layout is essential for optimizing workflow, minimizing transportation costs,
and ensuring smooth operations. Various layout types such as process layout, product layout,
fixed-position layout, and cellular layout serve different operational needs and can be
strategically employed based on the nature of the products or services being offered.

Material handling, on the other hand, encompasses the movement, protection, storage, and
control of materials throughout the manufacturing process. This includes the selection and use of
equipment such as forklifts, conveyors, and automated guided vehicles (AGVs), as well as the
development of systems that facilitate the efficient flow of materials from suppliers to production
lines and ultimately to customers. Effective material handling is crucial for reducing waste,
preventing damage to goods, ensuring safety, and enhancing productivity.

The interplay between facilities layout and material handling is profound; a well-designed layout
can significantly reduce the complexity and cost associated with material handling operations.
Conversely, inadequate material handling systems can lead to bottlenecks and inefficiencies that
undermine even the best-laid plans for facility layout. As industries evolve with advancements in
technology and changes in consumer demand, the integration of innovative material handling
solutions—such as automation and robotics—into facility design becomes increasingly
important.
Furthermore, considerations such as scalability, flexibility, and sustainability are becoming
integral to modern facilities layout and material handling strategies. Organizations are
increasingly adopting lean principles to eliminate waste and enhance value creation throughout
their operations. In this context, continuous improvement methodologies like Six Sigma are also
being applied to refine both layout designs and material handling processes.

In conclusion, the synergy between facilities layout and material handling is vital for optimizing
operational performance in any industrial setting. By strategically designing layouts that
facilitate efficient material flow and incorporating advanced handling technologies, organizations
can achieve significant improvements in productivity, cost-effectiveness, and adaptability to

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market changes. As industries continue to advance, ongoing research and innovation in these
areas will remain essential for maintaining competitive advantage in an ever-evolving landscape.

1. introduction/background
Facilities layout and material handling are critical components of industrial engineering and
operations management, influencing the efficiency and effectiveness of production processes and
logistics. As industries have evolved, particularly in the wake of globalization and technological
advancements, the significance of these elements has become increasingly pronounced.
Understanding the historical context, foundational concepts, and contemporary trends in facilities
layout and material handling is essential for organizations aiming to optimize their operations.
The origins of facilities layout and material handling can be traced back to the early days of
industrialization during the late 18th and early 19th centuries. The advent of the Industrial
Revolution marked a significant shift from agrarian economies to industrialized ones, leading to
the establishment of factories that required efficient organization of space and resources. Early
manufacturing operations were often characterized by rudimentary layouts that did not prioritize
efficiency, leading to wasted time and resources.
As production methods evolved, particularly with the introduction of assembly line techniques
by Henry Ford in the early 20th century, the importance of systematic facilities layout became
evident. Ford’s innovative approach to mass production necessitated a product-oriented layout
that streamlined operations and minimized transportation distances. This marked a turning point
in manufacturing, highlighting the need for strategic planning in both layout design and material
handling processes.
In the decades that followed, various management theories emerged, including Scientific
Management by Frederick Taylor, which emphasized efficiency and productivity through
systematic analysis of work processes. This era saw the development of more sophisticated
techniques for organizing facilities, including process layouts for job shops and product layouts
for assembly lines. The focus on optimizing material flow through effective handling systems
began to gain traction, leading to innovations in equipment and technology.
Facilities layout encompasses the arrangement of physical resources within a facility. It involves
strategic decisions about where to position equipment, workstations, storage areas, and employee
spaces to facilitate efficient workflow. The primary goal of an effective layout is to minimize
waste whether in terms of time, materials, or labor while maximizing productivity.
Several key factors influence the design of facilities layout:
1. Type of Production: Different production environments require distinct layout strategies.
For instance, continuous production processes benefit from product layouts that streamline
operations, while job shops may require process layouts that allow for flexibility in handling
diverse products.

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 Research method on facility layout design and material handling
2. Volume and Variety: The volume of production and variety of products significantly
impact layout decisions. High-volume production with low variety typically favors product
layouts, while low-volume, high-variety production may necessitate more flexible layouts.
3. Workflow: Understanding the flow of materials and information within a facility is crucial
for layout design. Analyzing workflows helps identify potential bottlenecks and inefficiencies,
allowing for adjustments that enhance overall performance.
4. Safety and Ergonomics: A well-designed layout considers the safety and comfort of
employees. Ensuring that workspaces are ergonomically designed can reduce the risk of injuries
and improve worker satisfaction.
5. Future Scalability: Organizations must also consider future growth when designing
facilities. A flexible layout can accommodate changes in production requirements or expansions
without requiring significant redesign.
facilities layout and material handling are foundational elements that significantly influence
operational efficiency within industrial environments. Their historical evolution reflects broader
changes in manufacturing practices, while contemporary trends highlight the need for
organizations to remain agile and responsive to market demands. By understanding the principles
underlying effective layout design and material handling systems, businesses can enhance
productivity, reduce costs, and improve overall performance in an increasingly competitive
landscape. As industries continue to evolve, ongoing research and innovation in these areas will
be essential for achieving operational excellence.
In blanket factories, effective facilities layout and material handling are crucial for optimizing
production efficiency and ensuring smooth operations. Companies often adopt specific
approaches to enhance these aspects
while facilities layout and material handling in blanket factories significant challenges due to
inefficiencies and lack of resources, there are opportunities for improvement. By addressing
weaknesses through better layout planning, organization, training, and worker feedback, factories
can enhance operational efficiency, reduce waste, and improve overall productivity. These
changes not only benefit the factory's performance but also contribute to a safer and more
comfortable work environment for employees.

2. Problem statement
The current state of the blanket factory is contributing to in efficiency and various operational
challenges poor machinery and workstation arrangement increase worker fatigue production time
and increase the risk of accident these issues result in decreased productivity increased operating
costs and frequent delays in meeting delivery deadlines.
Key Points of Lack in Facilities Layout and Material Handling

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 Research method on facility layout design and material handling
 Inefficient Workflow Design: The current layout does not facilitate a logical flow of
materials and processes, resulting in excessive movement of workers and materials, which
increases production time and reduces efficiency.
 Inadequate Storage Solutions: There is insufficient space and organization for raw
materials and finished products, leading to cluttered workspaces, difficulty in locating items,
and increased chances of damage or loss.
 Limited Use of Automation: The factory lacks modern automated material handling
systems (such as conveyor belts or automated guided vehicles), which could significantly
reduce manual labor and improve the speed and accuracy of material transport.
 Insufficient Training and Standardization: There is a lack of standardized
procedures for material handling, coupled with inadequate training for employees. This leads
to inconsistent practices, increased errors, and potential safety hazards during operations.
Observations and studies of mobility during the past year here have shown that workers moves
excessively between different part of the factory as I tried to explain above due to apparent
vertical layout problems specially in the finished part the company has to reduce the distance
between working part example the last part ( hydrolytic press and packing part) is very wide so if
they put all the second is to make a short distance between razing and packing room they can
assemble the metering sewing and cutting machine in the razing room.
To address these issues the plant redesigned the facility layout with the aim of streamlining
workflows, reducing unnecessary activity and increasing safety, therefore following the facility
layout system, the machines in the factory should be filled together according to its standards
which will reduce unnecessary wastage of time.

Literature review
 The design and management of facilities layout and material handling systems are
fundamental aspects of industrial engineering and operations management. A well-structured
course on these topics is essential for equipping students with the knowledge and skills
necessary to optimize production environments. This literature review examines the key
themes, methodologies, challenges, and pedagogical approaches relevant to a facilities layout
and material handling

Integration of Facilities Layout and Material Handling

The interplay between facilities layout and material handling is a vital area of focus in a
comprehensive course. Understanding this relationship allows students to design more effective
production environments
.
Simulation and Modeling
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 Research method on facility layout design and material handling
Simulation techniques are increasingly employed to analyze the interactions between facilities
layout and material handling systems. Courses may incorporate tools such as discrete-event
simulation to allow students to model different scenarios and assess layout changes' impacts on
material flow

Lean Manufacturing Principles

Lean manufacturing principles emphasize waste elimination across all processes, including
layout design and material handling (Womack Jones, 2003). Teaching these principles helps
students develop a mindset focused on continuous improvement.
A well-structured facilities layout and material handling course provides students with essential
knowledge and skills to optimize production environments. By covering various types of layouts,
material handling systems, safety considerations, and integration techniques, students are
equipped to tackle real-world challenges in operations management. Future courses should
continue to evolve by incorporating advanced technologies such as artificial intelligence and the
Internet of Things while emphasizing sustainability and ergonomic considerations.

Fig, working flow of debre birhan blanket production

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 Research method on facility layout design and material handling

4. Objectives of the thesis

his research endeavors to fulfill the subsequent general and specific objectives through the
successful execution of the thesis.
4.1 general objectives
the general objectives of facilities layout and material handling focus on creating an efficient,
safe, and adaptable environment that enhances productivity, reduces costs, and supports the
overall goals of the organization
4.2 specific objectives
1. Optimize Material Flow:
Design layouts that minimize the distance materials travel between processes, reducing handling
time and transportation costs.
2. Facilitate Efficient Work Processes
Arrange workstations and equipment to support a logical sequence of operations, ensuring that
each step in the process flows smoothly into the next.
3. Reduce Lead Times
Streamline the layout to decrease the time taken from order receipt to product delivery,
enhancing responsiveness to customer demands.
4. Enhance Space Utilization
Maximize the use of vertical and horizontal space, ensuring that every square foot contributes to
productivity.
5. Improve Accessibility
Ensure that tools, materials, and equipment are easily accessible to workers, reducing downtime
caused by searching for resources.

6. methodology of the study

1. Design of the Study
The study will adopt a descriptive research design, which is suitable for examining the current
state of facilities layout and material handling in a blanket factory. This design will allow for a
comprehensive analysis of existing processes, identification of inefficiencies, and
recommendations for improvements. The study will involve both qualitative and quantitative
approaches to gather in-depth insights and statistical data.

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 Research method on facility layout design and material handling
Method of Data Collection
Data will be collected using a combination of the following methods:Surveys and
Questionnaires: Structured surveys will be distributed to employees across various departments
(production, logistics, quality control) to gather information on their experiences with current
layout and material handling practices.
Interviews; Semi-structured interviews will be conducted with key stakeholders, including
management, supervisors, and floor workers. This will provide qualitative insights into
operational challenges and employee perspectives on potential improvements.
Observational Studies: Direct observation of the production process and material handling
activities will be carried out to identify workflow patterns, bottlenecks, and areas for
improvement. This method will help validate survey and interview findings.
Document Analysis: Existing records, such as production reports, inventory logs, and layout
diagrams, will be reviewed to understand historical performance and identify trends.
Case Studies: If applicable, case studies of similar manufacturing facilities that have
successfully improved their layout and material handling will be analyzed to extract best
practices.

Scope and Limitations of the Study

Scope: The study will focus specifically on the blanket manufacturing process within the
selected factory, examining all aspects of facilities layout and material handling.
It will cover various dimensions such as workflow efficiency, safety protocols, inventory
management, and employee satisfaction.
The time frame for data collection will encompass a three-month period to ensure adequate
representation of operational conditions.
Limitations:
The study may be limited by the availability of willing participants for surveys and interviews,
potentially affecting the breadth of qualitative data collected.
Observational studies may be influenced by external factors such as production schedules or
equipment malfunctions during the data collection period.

Significance of the Thesis

The significance of this thesis lies in its potential contributions to both academic knowledge and
practical applications within the manufacturing sector:
Academic Contribution: The study aims to fill gaps in existing literature on facilities
layout and material handling by providing empirical data from a specific industry context. It will

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contribute to the understanding of how layout design impacts operational efficiency in blanket
manufacturing.
Practical Implications: The findings will offer actionable recommendations for the blanket
factory to optimize its facilities layout and material handling processes. Improved efficiency can
lead to reduced operational costs, enhanced product quality, and increased employee satisfaction.
Industry Relevance: As industries increasingly focus on lean manufacturing principles, this
research will provide insights into best practices that can be adopted by other textile
manufacturers facing similar challenges.
Future Research Directions: The study may pave the way for future research on related
topics, such as the integration of technology in material handling or the impact of layout changes
on worker productivity.

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