Facility Layout Planning for Pyrolyzer Production Using Automated Layouts Design Program (ALDEP) Method

One important factor to consider in increasing productivity in a company is the design of the facility layout. PT Hari Mukti Teknik is keen producing pyrolysis machine to contribute to addressing waste issue in Indonesia. Currently, the facility layout at the company is not suitable to produce pyrolizers as it was set up to produce industrial scale washing machines. To improve production efficiency, PT Hari Mukti Teknik needs facility layout that can be optimized for pyrolizers. The purpose of this study is to provide a layout design proposal for the pyrolysis machine manufacturing process to obtain an effective and efficient process. Here, we used ALDEP method to produce layouts based on consideration of the level of relationship between departments. There were 4 alternatives for the manufacturing and production and two alternative layouts for employee and office area. The design for new layout was selected based on the closeness relationship between the departments. An overall facility layout plan that is required for the production of pyrolysis machines is a building area the total of 1045 m² covering manufacturing, production, employee, office and parking space areas

Scheduling With Alternatives Machine Using Fuzzy Inference System And Genetic Algorithm.

As the manufacturing activities in today's industries are getting more and more complex, it is required for the manufacturing company to have a good shop floor production scheduling to plan and schedule their production orders. Industri pengeluarcim kini telah berkembang pesat dan aktiviti pengeluarannya semakin kompleks, dengan itu syarikat pengeluar memerlukan jadual lantai pengeluaran (shop floor) yang terbaik untuk merancang permintaan pengeluaran (product)

Heuristic search methods and cellular automata modelling for layout design

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Spatial layout design must consider not only ease of movement for pedestrians under normal conditions, but also their safety in panic situations, such as an emergency evacuation in a theatre, stadium or hospital. Using pedestrian simulation statistics, the movement of crowds can be used to study the consequences of different spatial layouts. Previous works either create an optimal spatial arrangement or an optimal pedestrian circulation. They do not automatically optimise both problems simultaneously. Thus, the idea behind the research in this thesis is to achieve a vital architectural design goal by automatically producing an optimal spatial layout that will enable smooth pedestrian flow. The automated process developed here allows the rapid identification of layouts for large, complex, spatial layout problems. This is achieved by using Cellular Automata (CA) to model pedestrian simulation so that pedestrian flow can be explored at a microscopic level and designing a fitness function for heuristic search that maximises these pedestrian flow statistics in the CA simulation. An analysis of pedestrian flow statistics generated from feasible novel design solutions generated using the heuristic search techniques (hill climbing, simulated annealing and genetic algorithm style operators) is conducted. The statistics that are obtained from the pedestrian simulation is used to measure and analyse pedestrian flow behaviour. The analysis from the statistical results also provides the indication of the quality of the spatial layout design generated. The technique has shown promising results in finding acceptable solutions to this problem when incorporated with the pedestrian simulator when demonstrated on simulated and real-world layouts with real pedestrian data.This study was funded by the University Science of Malaysia and Kementerian Pengajian Tinggi Malaysia

Optimization of facility layout

Computer-aided layout technique, which appears to be the best approach to solving complex layout problems, is not commonly used in practice. One of the important reasons may be the generation of unrealistic layouts which results from ignoring the important practical constraints and objectives involved in layout problems. As one possible solution to this problem, a human planner can develop layout using a computer routine with those constraints and objectives in mind. However, the development of a heuristic procedure which incorporates human-like layout processes into a computer program could be a better solution;This dissertation provides the means of a realistic or a close to realistic layout development using important practical objectives and constraints involved in facility layout. Instead of ignoring those factors due to the difficulties of implementing them into mathematical statements, using them in the process of layout development will be helpful to reach an optimum or a near-optimum solution;An experimental system, FLUKES, has been constructed for testing purposes. This system develops layouts which include the practical factors involved in layout problems. These factors include architectural limitations, health/safety, user preferences, utilities, department shapes, future expansion plans, and energy savings as well as material handling costs. FLUKES uses these factors not only for the evaluation of a layout, but also for the search for a solution

Material handling optimization in warehousing operations

Tableau d’honneur de la Faculté des études supérieures et postdoctorales, 2018-2019.Les activités de distribution et d’entreposage sont des piliers importants de la chaîne d’approvisionnement. Ils assurent la stabilité du flux de matières et la synchronisation de toutes les parties prenantes du réseau. Un centre de distribution (CD) agit comme un point de découplage entre l’approvisionnement, la production et les ventes. La distribution comprend un large éventail d’activités visant à assurer la satisfaction de la demande. Ces activités passent de la réception au stockage des produits finis ou semi-finis, à la préparation des commandes et à la livraison. Les opérations d’un CD sont maintenant perçues comme des facteurs critiques d’amélioration. Elles sont responsables de la satisfaction d’un marché en évolution, exigeant des délais de livraison toujours plus rapides et plus fiables, des commandes exactes et des produits hautement personnalisés. C’est pourquoi la recherche en gestion des opérations met beaucoup d’efforts sur le problème de gestion des CDs. Depuis plusieurs années, nous avons connu de fortes avancées en matière d’entreposage et de préparation de commandes. L’activité de préparation de commandes est le processus consistant à récupérer les articles à leur emplacement de stockage afin d’assembler des commandes. Ce problème a souvent été résolu comme une variante du problème du voyageur de commerce, où l’opérateur se déplace à travers les allées de l’entrepôt. Cependant, les entrepôts modernes comportent de plus en plus de familles de produits ayant des caractéristiques très particulières rendant les méthodes conventionnelles moins adéquates. Le premier volet de cette thèse par articles présente deux importants et complexes problèmes de manutention des produits lors de la préparation des commandes. Le problème de préparation des commandes a été largement étudié dans la littérature au cours des dernières décennies. Notre recherche élargit le spectre de ce problème en incluant un ensemble de caractéristiques associées aux installations physiques de la zone de prélèvement, comme les allées étroites, et aux caractéristiques des produits (poids, volume, catégorie, fragilité, etc.). Une perspective plus appliquée à la réalité des opérations est utilisée dans notre développement d’algorithmes. Les déplacements liés à la préparation des commandes sont fortement influencés par le positionnement des produits. La position des produits dans la zone de prélèvement est déterminée par une stratégie d’affectation de stockage (storage assignment strategy). Beaucoup de ces stratégies utilisent de l’information sur les ventes des produits afin de faciliter l’accès aux plus populaires. Dans l’environnement concurrentiel d’aujourd’hui, la durée de vie rentable d’un produit peut être relativement courte. Des promotions peuvent également être faites pour pousser différents produits sur le marché. Le positionnement fourni par la stratégie d’hier ne sera probablement plus optimal aujourd’hui. Il existe plusieurs études mesurant l’impact d’une bonne réaffectation de produits sur les opérations de prélèvement. Cependant, ils étudient la différence des performances avec les positionnements passés et actuels. La littérature démontre clairement que cela apporte des avantages en termes d’efficacité. Toutefois, les déplacements nécessaires pour passer d’une position à une autre peuvent constituer une activité très exigeante. Ceci constitue le second volet de cette thèse qui présente des avancées intéressantes sur le problème de repositionnement des produits dans la zone de prélèvement. Nous présentons le problème de repositionnement des produits sous une forme encore peu étudiée aux meilleurs de nos connaissances : le problème de repositionnement. Plus précisément, nous étudions la charge de travail requise pour passer d’une configuration à l’autre. Cette thèse est structuré comme suit. L’introduction présente les caractéristiques et les missions d’un système de distribution. Le chapitre 1 fournit un survol de la littérature sur les principales fonctions d’un centre de distribution et met l’accent sur la préparation des commandes et les décisions qui affectent cette opération. Le chapitre 2 est consacré à l’étude d’un problème de préparation de commandes en allées étroites avec des équipements de manutention contraignants. Dans le chapitre 3, nous étudions un problème de préparation des commandes où les caractéristiques des produits limitent fortement les routes de prélèvement. Le chapitre 4 présente une variante du problème de repositionnement (reassignment) avec une formulation originale pour le résoudre. La conclusion suit et résume les principales contributions de cette thèse. Mots clés : Préparation des commandes, entreposage, problèmes de routage, algorithmes exacts et heuristiques, réaffectation des produits, manutention.Distribution and warehousing activities are important pillars to an effective supply chain. They ensure the regulation of the operational flow and the synchronization of all actors in the network. Hence, distribution centers (DCs) act as crossover points between the supply, the production and the demand. The distribution includes a wide range of activities to ensure the integrity of the demand satisfaction. These activities range from the reception and storage of finished or semi-finished products to the preparation of orders and delivery. Distribution has been long seen as an operation with no or low added value; this has changed, and nowadays it is perceived as one of the critical areas for improvement. These activities are responsible for the satisfaction of an evolving market, requiring ever faster and more reliable delivery times, exact orders and highly customized products. This leads to an increased research interest on operations management focused on warehousing. For several years, we have witnessed strong advances in warehousing and order picking operations. The order picking activity is the process of retrieving items within the storage locations for the purpose of fulfilling orders. This problem has long been solved as a variant of the travelling salesman problem, where the order picker moves through aisles. However, modern warehouses with more and more product families may have special characteristics that make conventional methods irrelevant or inefficient. The first part of this thesis presents two practical and challenging material handling problems for the order picking within DCs. Since there are many research axes in the field of warehousing operations, we concentrated our efforts on the order picking problem and the repositioning of the products within the picking area. The order picking problem has been intensively studied in the literature. Our research widens the spectrum of this problem by including a set of characteristics associated with the physical facilities of the picking area and characteristics of the product, such as its weight, volume, category, fragility, etc. This means that a more applied perspective on the reality of operations is used in our algorithms development. The order picking workload is strongly influenced by the positioning of the products. The position of products within the picking area is determined by a storage assignment strategy. Many of these strategies use product sales information in order to facilitate access to the most popular items. In today’s competitive environment, the profitable lifetime of a product can be relatively short. The positioning provided by yesterday’s assignment is likely not the optimal one in the near future. There are several studies measuring the impact of a good reassignment of products on the picking operations. However, they study the difference between the two states of systems on the picking time. It is clear that this brings benefits. However, moving from one position to another is a very workload demanding activity. This constitutes the second part of this thesis which presents interesting advances on the repositioning of products within the picking area. We introduce the repositioning problem as an innovative way of improving performance, in what we call the reassignment problem. More specifically, we study the workload required to move from one setup to the next. This thesis is structured as follows. The introduction presents the characteristics and missions of a distribution system. Chapter 1 presents an overview of the literature on the main functions of a DC and emphasizes on order picking and decisions affecting this operation. Chapter 2 is devoted to the study of a picking problem with narrow aisles facilities and binding material handling equipment. In Chapter 3, we study the picking problem with a set of product features that strongly constrain the picking sequence. Chapter 4 presents a variant of the reassignment problem with a strong and new formulation to solve it. The conclusion follows and summarizes the main contributions of this thesis. Key words: Order-picking, warehousing, routing problems, exact and heuristic algorithms, products reassignment, material handling

Interactive constraint-based space layout planning

Layout planning is the primordial design activity that determines the characteristics and performance of a building throughout its lifecycle. Due to its iterative nature, there is a growing interest in the automation of space layout planning to enhance the search for optimum design solutions. The approaches for automation range from constraint/heuristics-based to the application of numerical optimisation algorithms. Among these, the use of design constraints to guide the search of the solution space is well regarded due to its ability to model design problems of an applied nature with multiple objectives. Constraint-based approaches also allow interactivity between the designer and layout planning process, which simulates the iterative nature of creative design and can be integrated well with the existing design process. Interactivity also enhances the management of design knowledge through improved processing and visualisation of information. This paper presents a theoretical framework for interactive constraint-based layout optimisation with an implemented prototype for a hospital patient room interior layout. The theoretical framework was developed by analysing existing layout automation methods and interactive approaches through a review of relevant literature. Object-oriented computer programming was used to develop the prototype to demonstrate the proposed approach of interactive layout planning system. The framework augments the iterative design process by facilitating the active participation and sharing of the designer’s knowledge during the aggregation. With regard to the implementation of the framework in large problems, fast evaluation of design solution was found to be necessary to interact with the system in real time. Interactive constraint-based layout optimisation has, therefore, the ability to enhance the search process of optimum design solutions by augmenting the iterative nature of the creative design process

Shipping Configuration Optimization with Topology-Based Guided Local Search for Irregular Shaped Shipments

Manufacturer that uses containers to ship products always works to optimize the space inside the containers. Container loading problems (CLP) are widely encountered in forms of raw material flow and handling, product shipments, warehouse management, facility floor planning, as well as strip-packing nesting problems.Investigations and research conducted two decades ago were logistic orientated, on the basis of the empirical approaches

A methodology for controlling the consequences of demand variability in the design of manufacturing systems

Today's unprecedented demand changes flood the global market. Staying competitive is now a matter of responding quickly and cost-effectively to variability. To address this paradigm, flexibility is a key aspect to tackle. Studies show that integrating flexibility in design of systems increases their performance by 25%, yet application procedures are still not very well established. This dissertation proposes a solution methodology for this problem. Aiming control of demand variability consequences, an integrated approach of optimization, screening, and simulation modelling has been developed. Applied to a case study in the furniture manufacturing industry, the methodology highlighted numerous opportunities of improvement in the manufacturing site. Indeed, by applying a flexible design, the overall performance goals were reached and a plan of action was initiated.The results support the proposed methodology as a viable solution for the problem addressed, nevertheless future success involves more than the pure application of this procedure, as flexibility is also a way of thinking

Production Engineering and Management

It is our pleasure to introduce the 8th edition of the International Conference on Production Engineering and anagement (PEM), an event that is the result of the joint effort of the OWL University of Applied Sciences and the University of Trieste. The conference has been established as an annual meeting under the Double Degree Master Program “Production Engineering and Management” by the two partner universities. This year the conference is hosted at the university campus in Lemgo, Germany. The main goal of the conference is to offer students, researchers and professionals in Germany, Italy and abroad, an opportunity to meet and exchange information, discuss experiences, specific practices and technical solutions for planning, design, and management of manufacturing and service systems and processes. As always, the conference is a platform aimed at presenting research projects, introducing young academics to the tradition of symposiums and promoting the exchange of ideas between the industry and the academy. This year’s special focus is on Supply Chain Design and Management in the context of Industry 4.0, which are currently major topics of discussion among experts and professionals. In fact, the features and problems of Industry 4.0 have been widely discussed in the last editions of the PEM conference, in which sustainability and efficiency also emerged as key factors. With the further study and development of Direct Digital Manufacturing technologies in connection with new Management Practices and Supply Chain Designs, the 8th edition of the PEM conference aims to offer new and interesting scientific contributions. The conference program includes 25 speeches organized in seven sessions. Two are specifically dedicated to “Direct Digital Manufacturing in the context of Industry 4.0”. The other sessions are covering areas of great interest and importance to the participants of the conference, which are related to the main focus: “Supply Chai n Design and Management”, “Industrial Engineering and Lean Management”, “Wood Processing Technologies and Furniture Production”, and “Management Practices and Methodologies”. The proceedings of the conference include the articles submitted and accepted after a careful double-blind refereeing process