F a c u l t y o f M E C H A N I C A L E N G I N E E R I N G M A N A G E M E N T A N D M A N U F A C T U R I N G E N G I N E E R I N G FACTORY LAYOUT P...
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Faculty of MECHANICAL ENGINEERING MANAGEMENT AND MANUFACTURING ENGINEERING
FACTORY LAYOUT PLANNING AND OPTIMIZATION
DESIGN OF
MANUFACTURING SYSTEM
BY THE THREE METHODS FOR A GIVEN PRODUCTION PROGRAM
AUTHORS:
PROJECT:
TUTOR:
Magdalena Żuk, 205222
Day:
Tuesdays
Ender Tas, 224244
Time:
11:15
Week:
even
Dr. inż. Maria Rosienkiewicz
LIST OF CONTENTS
Introduction to our project ........................................... 5
I.
IV.
NECESSARY NUMBER OF MACHINES ................. 7
II.
SELECTION OF MACHINERY ................................ 8
III.
ARRANGEMENT OF WORKSTATIONS ............... 10 a.
COSTS OF THE PRODUCTION PROCESS .......... 23
a.
metallurgical materials .................................. 23
b.
labor workers ................................................... 23
c.
workplaces....................................................... 24
d.
technological process ................................... 24
e.
transportation .................................................. 25
V.
COST CALCULATION ......................................... 26
MST algorithm .................................................. 10 + drawing of MST layout
a.
MST algorithm .................................................. 26
b.
ROC algorithm ................................................ 15 + drawing of ROC layout
b.
ROC algorithm ................................................ 27
c.
Schmigalla triangles algorithm ..................... 27
c.
Schmigalla triangles algorithm ..................... 19 + drawing of SCHMIGALLA layout
COMPARISON & CONCLUSIONS ................................ 29
4
INTRODUCTION TO OUR PROJECT Our task is creating factory layout in 3 different methods. After selection of the machinery, we needed to arrange workstations according to MST, ROC and Schmigalla triangles algorithm methods. In order to draw layouts, we used calculated algorithms. We had to proper these layouts for 3 parts: Number 5 Shaft, Number 8 Bush and Number 4 Shaft.
Part no. 5 Part name shaft Material 20H Operation no.
10
20
30
40
50
60
70
80
Work station
Saw
Lathe
Splineway miller
Horizontal miller
Shaft grinder
Splines grinder
Lathe
QC
run time [h]
0,020
0,314
0,060
0,543
0,166
0,370
0,016
0,05
setup time [h]
0,15
0,52
0,30
0,50
0,32
0,40
0,30
0,1
io
0,04
0,55
0,11
0,94
0,29
0,64
0,03
0,09
5
Part no. 8 Part name bush Material B555 10
20
30
40
50
60
70
Work station
Lathe
Broaching machine
Locksmith tools
Lathe
Vertical miller
Shaft grinder
QC
run time [h]
0,140
0,023
0,033
0,048
0,028
0,052
0,050
setup time [h]
0,47
0,28
0,09
0,30
0,30
0,27
0,10
io
0,29
0,05
0,07
0,10
0,06
0,11
0,09
Operation no.
Part no. 4 Part name shaft Material 40H Operation no.
10
20
30
40
50
Work station
Saw
Lathe
Splineway miller
Shaft grinder
QC
run time [h]
0,015
0,212
0,280
0,260
0,050
setup time [h]
0,15
0,52
0,30
0,32
0,10
io
0,04
0,59
0,78
0,72
0,09
6
I. NECESSARY NUMBER OF MACHINES Using data below and from the previous point we can calculate io from formula:
DATA Number of pieces (n): Element a:
500
Element b:
600
Element c:
800
tpz - setup time
factor of day utilisation (𝜳):
0,9
tj - run time
number of days (D):
20
number of shift (l):
2
Now we can calculate amount of each machine:
work station
MASHINERY Saw
Lathe
Splineway miller
Horizontal miller
Vertical miller
Shaft grinder
Splines grinder
Broaching machine
Locksmith tools
QC
∑ io
0,08
1,62
0,88
0,94
0,06
1,12
0,64
0,05
0,05
0,26
amount
1
2
1
1
1
2
1
1
1
1
7
II. SELECTION OF MACHINERY
SAW
LATHE
HORIZONTAL MILLER
SPLINWAY MILLER
KHK 350
Sinus 330/2000 D
X-Graph 650 CNC
Servomill
SHAFT GRINDER
VERTICAL MILLER
BROACHING MACHINE
SPLINES GRINDER
RSM 1000 C
VFM 5
SSB32Xn
REFORM PSM
8
Dimensions and other information:
machine 1
saw
2
lathe
3
splineway miller
4
horizontal miller
5
vertical miller
6
shaft grinder
7
splines grinder
8
broaching machine
9
locksmith tools
10
QC
dimensions [mm]
price (PLN)
demand of electricity
1680
14500
1,7
1230
1600
6500
3,2
2540
2160
2240
24770
1,3
2000
2000
2330
48500
4,25
2520
2100
2150
22150
3,6
2500
1600
1515
18400
2,12
3500
1500
1900
32500
2,46
1300
1000
1000
12200
3,2
1300
1000
750
1880
0
1300
1000
750
1000
0
lenght
width
height
1100
640
3210
9
III. ARRANGEMENT OF WORKSTATIONS a. MST ALGORITHM We arranged workstations with MST Algorithm method to design our manufacturing system and layouts by given production program. Part routing information matrix
Flow matrix fij MACHINE 1 1 M A C H I N E
2
3
4
5
6
7
8
9
52
0
0
0
0
0
0
0
0
52
0
30
0
20
30
30
20
20
0
32
0
0
0
0
0
20
0
0
0
0
30
0
0
0
0
20
0
0
62
0
0
30
0
2
52
3
0
52
4
0
0
20
5
0
30
0
0
6
0
0
32
20
30
7
0
20
0
0
0
20
8
0
30
0
0
0
0
0
9
0
30
0
0
0
0
0
30
10
0
20
0
0
0
62
0
0
0
10
0 0
10
Some data to prepare the clearance matrix dij Machine lengths l 1
1,10
2
3,21
3
2,54
4
2,00
5
2,52
6
1,50
7
0,40
8
0,84
9
1,30
10
1,30
Distance dimension [m] Machines dimensions - horizontal projection
Distance
Symbol
Between sides of the machines
k access
1500x750
from 1500x750 to 3000x2000
0,4
0,5
from 3000x2000 over 5000x3000 to 5000x3000
0,7
0,9
Clearance matrix dij MACHINE 1 1 M A C H I N E
2 0,7
3
4
5
6
0 0,7
7
8
0
0
0
0
0
0
0
0
0,7
0
0,7
0,7
0,7
0,7
0,5
0
0,5
0
0
0
0
0
0,5
0
0
0
0
0,5
0
0
0
0
0,5
0
0
0,5
0
0
0
0,4
0
2
0,7
3
0
4
0
0
0,5
5
0
0,7
0
0
6
0
0
0,5
0,5
0,5
7
0
0,7
0
0
0
0,5
8
0
0,7
0
0
0
0
0
9
0
0,7
0
0
0
0
0
0,4
10
0
0,7
0
0
0
0,5
0
0
0,7
9
10
0 0
Select the largest element in the matrix and the corresponding i, j. Denote this pair of i,j as i*, j*. Connect machines i*, j*.
f ' ij ( f ij )( d ij 0 ,5 ( l i l j )
11
Adjacency weight matrix f'ij
MACHINE 1 1 M A C H I N E
2 148,46
3
4
5
6
0 185,9
7
8
9
10
0
0
0
0
0
0
0
0
106,95
0
50,05
81,75
88,65
59,1
55,4
0
80,64
0
0
0
0
45
0
0
0
0
75,3
0
0
0
0
28,95
0
0
117,8
0
0
44,1
0
2
148,46
3
0
4
0
0
55,4
5
0
106,95
0
0
6
0
0
80,64
45
75,3
7
0
50,05
0
0
0
28,95
8
0
81,75
0
0
0
0
0
9
0
88,65
0
0
0
0
0
44,1
10
0
59,1
0
0
0
117,8
0
0
0
1
2
3
4
5
6
7
8
9
10
148,46
0
0
0
0
0
0
0
0
0
106,95
0
50,05
81,75
88,65
59,1
55,4
0
80,64
0
0
0
0
0
45
0
0
0
0
0
0
0
0
28,95
0
0
117,8
0
0
44,1
0
185,9
0
0
connect machines:
2
2, 3 3
0
MACHINE
1 M A C H I N E
2
148,46
3
0
185,9
185,9
4
0
0
5
0
106,95
0
0
6
0
0
80,64
45
75,3
7
0
50,05
0
0
0
28,95
8
0
81,75
0
0
0
0
0
9
0
88,65
0
0
0
0
0
44,1
10
0
59,1
0
0
0
117,8
0
0
55,4
75,3
0
12
0 0
connect machines:
1
1, 2 2
3
MACHINE 1 1 M A C H I N E
2
3
4
5
6
7
8
9
10
148,46
0
0
0
0
0
0
0
0
185,9
0
106,95
0
50,05
81,75
88,65
59,1
55,4
0
80,64
0
0
0
0
0
45
0
0
0
0
75,3
0
0
0
0
28,95
0
0
117,8
0
0
0
44,1
0
2
148,46
3
0
185,9
4
0
0
55,4
5
0
106,95
0
0
6
0
0
80,64
45
75,3
7
0
50,05
0
0
0
28,95
8
0
81,75
0
0
0
0
0
9
0
88,65
0
0
0
0
0
44,1
10
0
59,1
0
0
0
117,8
0
0
0
5
6
7
8
9
connect machines:
1
3, 6 2
3
6
3
6
0
MACHINE 1
148,46
1 M A C H I N E
2
10
3
4
0
0
0
0
0
0
0
0
185,9
0
106,95
0
50,05
81,75
88,65
59,1
55,4
0
80,64
0
0
0
0
45
0
0
0
0
75,3
0
0
0
0
28,95
0
0
117,8
0
0
44,1
0
2
148,46
3
0
4
0
0
55,4
5
0
106,95
0
0
6
0
0
80,64
45
75,3
7
0
50,05
0
0
0
28,95
8
0
81,75
0
0
0
0
0
9
0
88,65
0
0
0
0
0
44,1
10
0
59,1
0
0
0
117,8
0
0
185,9
0
0
13
0 0
connect machines:
1
6, 10 2
10
MACHINE 1 1 M A C H I N E
2
3
4
5
6
7
8
9
10
148,46
0
0
0
0
0
0
0
0
0
106,95
0
50,05
81,75
88,65
59,1
55,4
0
80,64
0
0
0
0
45
0
0
0
0
75,3
0
0
0
0
28,95
0
0
117,8
0
0
0
44,1
0
185,9
connect machines:
2
148,46
3
0
4
0
0
55,4
5
0
106,95
0
0
6
0
0
80,64
45
75,3
7
0
50,05
0
0
0
28,95
8
0
81,75
0
0
0
0
0
9
0
88,65
0
0
0
0
0
44,1
10
0
59,1
0
0
0
117,8
0
0
0
1
2
3
4
5
6
7
8
9
10
148,46
0
0
0
0
0
0
0
0
0
106,95
0
50,05
81,75
88,65
59,1
55,4
0
80,64
0
0
0
0
45
0
0
0
0
75,3
0
0
0
0
28,95
0
0
117,8
0
0
0
44,1
0
185,9
0
9
9, 5, 1 5
1
next higher number MACHINE 5 (want to be next to MACHINE 2)
2
&
so - MACHINE 5 next to MACHINE 1
3
6
10
next higher number MACHINE 9 (want to be next to MACHINE 2) so - MACHINE 9 next to MACHINE 5
0
MACHINE
1 M A C H I N E
2
148,46
3
0
185,9
4
0
0
55,4
5
0
106,95
0
0
6
0
0
80,64
45
75,3
7
0
50,05
0
0
0
28,95
8
0
81,75
0
0
0
0
0
9
0
88,65
0
0
0
0
0
44,1
10
0
59,1
0
0
0
117,8
0
0
185,9
0
connect machines:
8
9
5
1
2
3
6
1
2
3
6
10
4
7
next higher number - MACHINE 4 (want to be next to MACHINE 3 & 6)
&
so - MACHINE 4 next to MACHINE 10 next higher number - MACHINE 7 (want to be next to MACHINE 2 and 6)
so - MACHINE 7 next to MACHINE 4
0
14
5
so - MACHINE 8 next to MACHINE 9
0
10
9
connect machines: 10, 4, 7
next higher number - MACHINE 8 (want to be next to MACHINE 2 and 9)
So, order of our machinery form MST algorithm is:
8
8, 9
4
7
b. ROC ALGORITHM We arranged workstations with Rank Order Clustering Algorithm Method (ROC) to design our manufacturing system and layouts by given production program. Part-machine processing indicator matrix
PART
MACHINE saw
lathe - S
lathe - B
splinway miller
horizontal miller
vertical miller
1
2
3
4
5
6
1
1
1
1
5 SHAFT /20H 8 BUSH /B555
Step 1 Step 2
BW BV
1
7
8
1
1
4 SHAFT /40H
shaft grinder - shaft grinder S B
broaching machine
locksmith tools
QC - S
QC - B
9
10
11
12
13
1
1
1
splines grinder
1
1
1
1
1
1
1
1
m= 13 Binary values and weights for the row and columns of a part-machine processing indicator matrix MACHINE m-j
j
BWj=2
P A R T
1
2
3
4
5
6
horizontal miller
vertical miller
128
machines:
saw
lathe - S
lathe - B
splinway miller
i
BW
4096
2048
1024
512
256
1
5 SHAFT/20H
1
1
1
1
2
8 BUSH/B555
3
4 SHAFT/40H
1
8
64
32
1
1 1
7
shaft grinder shaft grinder -S -B
1 1
15
10
11
12
13
broaching machine
locksmith tools
QC - S
QC - B
16
8
4
2
1
1 1
1
9 splines grinder
6994
1 1
1
1 1
BV
1193 6722
Step 3
Rank: i MACHINE
P A R T
Step 4
j
1
2
3
4
5
6
machines:
saw
lathe - S
lathe - B
splinway miller
horizontal miller
vertical miller
i
BW
4096
2048
1024
512
256
128
1
5 SHAFT/20H
1
1
1
1
2
4 SHAFT/40H
1
1
1
3
8 BUSH/B555
8
shaft grinder shaft grinder -S -B
64
9
10
11
12
13
splines grinder
broaching machine
locksmith tools
QC - S
QC - B
16
8
4
2
1
32
1
1
1
1
1
1
1
BV
1
6994
1
6722
1
1
1193
i: 1-6 BW
Step 5
7
n= 3
BV MACHINE
P A R T
j
1
2
3
4
5
6
machines:
saw
lathe - S
lathe - B
splinway miller
horizontal miller
vertical miller
i
BV
7
7
2
7
5
2
1
5 SHAFT/20H
1
1
1
1
2
4 SHAFT/40H
1
1
1
3
8 BUSH/B555
7
8
shaft grinder shaft grinder -S -B
7
2
1
9
10
11
12
13
splines grinder
broaching machine
locksmith tools
QC - S
QC - B
5
2
2
7
2
1
1
1
1
16
1
1
1
BWi=2n-i BW
1
4
1
2 1
1
Step 6
Rank: j
MACHINE
i P A R T
1 2 3
j
1
2
4
7
12
5
9
3
6
8
10
11
13
machines:
saw
lathe - S
splinway miller
shaft grinder -S
QC - S
horizontal miller
splines grinder
lathe - B
vertical miller
shaft grinder -B
broaching machine
locksmith tools
QC - B
BV
7
7
7
7
7
5
5
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
5 SHAFT/20H 4 SHAFT/40H 8 BUSH/B555
4 2 1
1
1
1
1
After doing this algorithm again we will have still the same order of machine so we can say that we have 2 clusters. The first cluster: machines with BV value 7 and 5, and the second cluster: machines with BV value 2. In layouts we put it in 2 groups - the distance between the machines we will take from norms.
CLUSTER 1 -
CLUSTER 2 -
BW
saw
lathe - S
splinway miller
shaft grinder -S
QC - S
horizontal miller
lathe - B
vertical miller
shaft grinder -B
broaching machine
locksmith tools
QC - B
17
splines grinder
1
1
18
c. SCHMIGALLA TRIANGLES ALGORITHM We arranged workstations with Schmigalla’s triangles method to design our manufacturing system and layouts by given production program. First of all we selected the pair of elements from the flow matrix and calculated them.
Lathe
Splineway miller
Horizontal miller
Vertical miller
Shaft grinder
Splines grinder
Broaching machine
Locksmith tools
QC
1
Saw
Routing Information Matrix
MACHINES
Item
Quantity
1
2
3
4
5
6
7
8
9
10
5 SHAFT/20H
500
1
2, 7
3
4
0
5
6
0
0
8
8 BUSH/B555
600
0
1, 4
0
0
5
6
0
2
3
7
4 SHAFT/40H
800
1
2
3
0
0
4
0
0
0
5
3 800 0
1 2 3 4 5 6 7 8 9 10
1300 0 0 0 0 0 0 0 0
2 1300 1300 0 600 0 500 600 600 500
3 0 1300 500 0 800 0 0 0 0
0 500 0 0 0 0
Flow matrix 5 6 0 0 600 0 0 800 0 500 600 600 0 500 0 0 0 0 0 1400
4 0 0 500
7 0 500 0 0 0 500 0 0 0
8 0 600 0 0 0 0 0 600 0
9 0 600 0 0 0 0 0 600 0
Object 6 10 ∑
1 0 0 0
2 0 500 500
3 800 0 800
4 500 0 500
5 600 0 600
7 500 0 500
8 0 0 0
9 0 0 0
max 800
Place 6 10 ∑
A 2 1 1600
B 2 1 1600
C 1 1 800
D 1 2 800
E 1 2 800
F 1 2 800
G 1 1 800
H 2 1 1600
min 800
19
10 0 500 0 0 0 1400 0 0 0
2 0 500 1300
1 0 0 0 1300
Object 6 10 3 ∑
1 0 0 0 0
2 0 500 1300 1800
4 500 0 500 1000
5 600 0 0 600
7 500 0 0 500
8 0 0 0 0
9 0 0 0 0
Place 6 10 3 ∑
A 2 1 2 3100
B 2 1 1 1800
C 2 2 1 2300
D 2 2 1 2300
E 1 2 1 2300
F 1 2 2 3600
G 1 2 2 3600
Object 6 10 3 2 ∑
1 0 0 0 1300 1300
4 500 0 500 0 1000
5 600 0 0 600 1200
7 500 0 0 500 1000
8 0 0 0 600 600
9 0 0 0 600 600
Place 6 10 3 2 ∑
A 2 1 2 1 1300
B 3 2 2 1 1300
C 3 2 2 1 1300
D 2 2 1 1 1300
E 2 2 1 2 2600
F 1 2 1 2 2600
20
max 1800
H 1 1 2 3100
I 2 1 2 3100
min 1800
max 1300
G 1 2 2 3 3900
H 1 2 2 3 3900
I 1 1 2 2 2600
J 2 1 2 2 2600
min 1300
5 600 0 0 600 0
4 500 0 500 0 0 0
Object 6 10 3 2 1 ∑
4 500 0 500 0 0 1000
5 600 0 0 600 0 1200
7 500 0 0 500 0 1000
8 0 0 0 600 0 600
9 0 0 0 600 0 600
Place 6 10 3 2 1 ∑
A 2 1 2 1 1 1800
B 3 2 3 2 1 3000
C 4 3 3 2 1 3600
D 4 3 3 2 1 3600
E 3 2 2 1 1 2400
Object 6 10 3 2 1 5 ∑
4 500 0 500 0 0 0 1000
7 500 0 0 500 0 0 1000
8 0 0 0 600 0 0 600
9 0 0 0 600 0 0 600
Place 6 10 3 2 1 5 ∑
A 2 1 2 1 1 3 2000
B 3 2 3 2 1 4 3000
C 4 3 3 2 1 4 3500
D 4 3 3 2 1 4 3500
21
max 1200
min 1800 F 2 2 1 1 2 1800
G 2 2 1 2 3 2400
H 1 2 1 2 3 1800
I 1 2 1 3 4 2400
J 1 2 2 3 4 2400
K 1 1 2 2 3 1800
L 2 1 2 2 2 2400
max 1000
min 1500 E 3 2 2 1 1 3 2500
F 2 2 1 1 2 2 1500
G 2 2 1 2 3 1 1500
H 2 3 2 3 4 1 2000
I 2 3 2 3 4 1 2000
J 1 2 2 3 4 1 1500
K 1 2 2 3 4 2 1500
L 1 1 2 2 3 2 1500
M 2 1 2 2 2 3 2000
I
7 500 0 0 500 0 0 0
Place 6 10 3 2 1 5 4 ∑
A 2 1 2 1 1 3 3 1500
I
Place 6 10 3 2 1 5 4 7 ∑
A 3 2 3 2 1 4 4 1 1200
F
C 4 3 3 2 1 4 5 3000
D 4 3 3 2 1 4 5 3000
4
6
10
B 4 3 3 2 1 4 5 2 1200
F
C 4 3 3 2 1 4 5 2 1200
E
D 3 2 2 1 1 3 4 2 600
B C
1 D
E
E 3 2 2 1 1 3 4 2000
F 2 2 1 1 2 2 3 1500
7
A 1
2
3
5 G
8 0 0 0 600 0 0 0 0
G
B 3 2 3 2 1 4 4 2500
H
A
2
3
5 H
N 10
6
4
J
M
L
K
D
E 2 2 1 1 2 2 3 2 600
G 2 2 1 2 3 1 2 2000
H 2 3 2 3 4 1 2 2500
Object 6 10 3 2 1 5 4 ∑
7 500 0 0 500 0 0 0 1000
8 0 0 0 600 0 0 0 600
9 0 0 0 600 0 0 0 600
I 2 3 2 3 4 1 1 2500
J 2 3 3 4 5 2 1 3000
K 2 3 3 4 5 2 1 3000
L 1 2 2 3 4 2 1 2000
Object 6 10 3 2 1 5 4 7 ∑
8 0 0 0 600 0 0 0 0 600
9 0 0 0 600 0 0 0 0 600
J 2 3 3 4 5 2 1 4 2400
K 1 2 2 3 4 2 1 3 1800
L 1 1 2 2 3 2 2 2 1200
B C
F 2 2 1 2 3 1 2 3 1200
G 2 3 2 3 4 1 2 4 1800
H 2 3 2 3 4 1 1 4 1800
I 2 3 3 4 5 2 1 4 2400
22
max 1000
min 1500 M 1 1 2 2 3 2 2 1500
N 2 1 2 2 2 3 3 2000
max 600
min 600 M 2 1 2 2 2 3 3 1 1200
N 3 1 3 2 2 4 4 1 1200
And the final order of machinery is:
IV. COSTS OF THE PRODUCTION PROCESS All data which is needed to calculate cost: Factory rent Schmigalla
Production hall
a.
Factory lighting
Surface
Unit
Price 1 m^2 [zł]
900
m^2
15
Quantity
Nominal power [kW]
9
0,40
Lightbulbs
1 lightbulb for 10^m
METALLURGICAL MATERIALS Materials
Factory rent MST
Production hall
Units
Value of a single purchase [zł]
shaft - 20H
500
kg
6,00
bush - B555
600
kg
20,00
shaft - 40H
800
kg
8,00
Factory lighting
Surface
Unit
Price 1 m^2 [zł]
500
m^2
15
Factory rent ROC
Production hall
Quantity
Lightbulbs
Quantity
Nominal power [kW]
5
0,40
1 lightbulb for 10^m
b.
Emloyees
Factory lighting
Surface
Unit
Price 1 m^2 [zł]
800
m^2
15
Lightbulbs
Quantity
Nominal power [kW]
8
0,40
LABOR WORKERS
1 lightbulb for 10^m
23
Mark
Quantity of workers per shift
Emloyee salary [zł/month]
Qualified worker
QW
6
6000,00
Non-qualified worker
NQW
7
3500,00
c.
d.
WORKPLACES
TECHNOLOGICAL PROCESS
Machines and tools
Technological process 1 - Shaft 5
Mark
Quantity
Price [zł]
Depreciati on rate [%]
Nominal power [kW]
Operations
Tj [h/piece]
Type od emloyee
Machines
Machine 1
saw
1
14500,00
14%
1,70
Operation 1
0,020
NQW
Saw
Machine 2
lathe
2
6500,00
14%
3,20
Operation 2
0,314
NQW
Lathe
Machine 3
splineway miller
1
24770,00
14%
1,30
Operation 3
0,060
QW
Splineway miller
Machine 4
horizontal miller
1
48500,00
14%
2,25
Operation 4
0,543
NQW
Horizontal miller
Machine 5
vertical miller
1
22150,00
14%
3,60
Operation 5
0,166
QW
Shaft Grinder
shaft grinder
Operation 6
0,370
QW
Splines Grinder
Machine 6
2
18400,00
14%
2,12
Operation 7
0,016
NQW
Lathe
Machine 7
splines grinder
1
32500,00
14%
2,46
Operation 8
0,05
QW
QC
Machine 8
broaching machine
1
12200,00
14%
3,20
Machine 9
locksmith tools
1
1880,00
14%
0,00
Machine 10
QC
1
1000,00
14%
0,00
Technological process 2 - Shaft 4
Cost of electricity: Electricity Price per kWh
0,55
zł
24
Operations
Tj [h/piece]
Type od emloyee
Machines
Operation 1
0,015
NQW
Saw
Operation 2
0,212
NQW
Lathe
Operation 3
0,280
QW
Splineway miller
Operation 4
0,260
QW
Shaft Grinder
Operation 5
0,050
QW
QC
Technological process 1 - Bush 8 Operations
Tj [h/piece]
Type od emloyee
Machines Transportation ROC
Operation 1
0,140
NQW
Lathe
Operation 2
0,023
NQW
Broaching Machine
Operation 3
0,033
QW
Locksmith tools
Operation 4
0,048
NQW
Lathe
Operation 5
0,028
NQW
Vertical Miller
Operation 6
0,052
QW
Shaft Grinder
Operation 7
0,050
QW
QC
e.
Transportation MST Unit
Length of transportation path
Unit
Shaft 5
0,00005
zł/m
80,00
m
Shatf 4
0,00005
zł/m
60,00
m
Bush 8
0,00005
zł/m
90,00
m
Unit
Length of transportation path
Unit
Shaft 5
0,00005
zł/m
70,00
m
Shatf 4
0,00005
zł/m
36,00
m
Bush 8
0,00005
zł/m
64,00
m
Transportation Schmigalla
TRANSPORTATION
The average cost of transporting an item for 1 meter
The average cost of transporting an item for 1 meter
25
The average cost of transporting an item for 1 meter
Unit
Length of transportation path
Unit
Shaft 5
0,00005
zł/m
70,00
m
Shatf 4
0,00005
zł/m
60,00
m
Bush 8
0,00005
zł/m
95,00
m
V. COST CALCULATION a. MST ALGORITHM
Shaft 5
VARIABLE COSTS OF 2nd ELEMENT components
Price [zł/unit]
0,16
Shaft 4
VARIABLE COSTS OF 3rd ELEMENT components
Price [zł/unit]
0,24
QW salary
72 000,00
Saw
0,01
Saw
0,01
NQW salary
49 000,00
Lathe
0,80
Lathe
0,80
Materials
7 500,00
Materials
Factory rent
components
Price [zł/unit]
Bush 8
Lathe
Broaching Machine
Price [zł/unit]
0,10
0,80
0,05
miller Horizontal
Machine 1
169,17
Machine 2
75,83
miller Shaft Grinder
Machine 3
288,98
Splines Grinder
Machine 4
565,83
Machine 5
258,42
Machine 6
214,67
Machine 7
379,17
Machine 8
142,33
Machine 9
21,93
Machine 10
11,67
Sum
0,27
0,45
Splineway miller
0,15
0,55
QC
0,00
Locksmith tools
0,01
Lathe
0,15
Vertical Miller
0,05
0,61
Shaft Grinder
0,20
Lathe
0,50
QC
0,00
QC
0,00
Transportation
0,004
Sum
3,90
1,10
Shaft Grinder
Electricity
the product
Splineway
Transportation
0,003
Sum
1,75
130 980,00
26
T
352,00
Electricity
associated with
T
indirectly
Electricity
Electricity
T
Depreciation rate ***
Electricity
Employees
Rent
components
VARIABLE COSTS OF 1st ELEMENT
Materials
FIXED COSTS
Transportation Sum
0,0045 1,36
b. ROC ALGORITHM
VARIABLE COSTS OF 2nd ELEMENT
Price [zł/unit]
components
Rent
12 000,00
QW salary
72 000,00
Saw
0,01
Saw
0,01
NQW salary
49 000,00
Lathe
0,31
Lathe
0,50
0,16
Shaft 4
0,24
components Bush 8
Lathe Broaching Machine
Price [zł/unit] 0,10
0,80 0,05
Electricity
121,68
Machine 2
1 124,56
Machine 3
957,85
Splines Grinder
0,61
Machine 4
100,34
Lathe
0,50
Machine 5
440,32
QC
0,00
Machine 6
24,00
Machine 7
1 456,55
Machine 8
1 055,19
Machine 9
67,70
Machine 10 Sum
miller Shaft Grinder
Transportation Sum
0,45 1,10
0,0035 3,41
44,50 138 955,89
27
miller
0,15
Shaft Grinder
0,55
QC
0,00
Transportation Sum
0,0018 1,45
Locksmith
Electricity
Horizontal
Machine 1
Splineway
T
miller
0,27
Electricity
the product
Splineway
T
associated with
563,20
Electricity
indirectly
T
Depreciation rate ***
Electricity
Factory rent
Shaft 5
VARIABLE COSTS OF 3rd ELEMENT
Price [zł/unit]
Employees
Materials
components
Materials
VARIABLE COSTS OF 1st ELEMENT Price [zł/unit]
Materials
FIXED COSTS components
tools
0,01
Lathe
0,15
Vertical Miller
0,05
Shaft Grinder
0,20
QC
0,00
Transportation Sum
0,0032 1,36
c. SCHMIGALLA TRIANGLES ALGORITHM
Employees
QW salary NQW salary
VARIABLE COSTS OF 2nd ELEMENT
Price [zł/unit]
components
Shaft 5
0,16
72 000,00
Saw
49 000,00
Lathe
VARIABLE COSTS OF 3rd ELEMENT
Price [zł/unit]
Shaft 4
0,24
0,01
Saw
0,01
0,80
Lathe
0,80
components
Price [zł/unit]
0,10
Bush 8
Lathe Broaching Machine
0,80,15 0,90
Electricity
Horizontal
0,27
Machine 1
121,68
Machine 2
1 124,56
Machine 3
957,85
Splines Grinder
Machine 4
100,34
Lathe
Machine 5
440,32
QC
0,00
Machine 6
24,00
Machine 7
1 456,55
Machine 8
1 055,19
Machine 9
67,70
Machine 10
44,50
Sum
miller Shaft Grinder
Transportation Sum
0,45
Splineway miller
0,15
0,40 0,05
0,61
Shaft Grinder
0,20
0,50
QC
0,00
3,90
140 526,29
28
0,00
0,00
Lathe
0,0035
0,55
QC
tools
Vertical Miller
1,10
Shaft Grinder
Locksmith Electricity
miller
Transportation
0,003
Sum
1,75
T
the product
Splineway
Electricity
633,60
T
associated with
Electricity
indirectly
T
Depreciation rate ***
Materials
Rent
13 500,00
Electricity
Factory rent
components
Materials
VARIABLE COSTS OF 1st ELEMENT Price [zł/unit]
Materials
FIXED COSTS components
Transportation Sum
0,00475 1,65
COMPARISON & CONCLUSIONS MST
ROC
SCHMIGALLA
LAYOUT COMPARISON The smallest production hall is in MST method. Total space estimated 500 sq m (50x10). Every building which we can rent on the market, has ROC method is one of the best way to have different shapes. That’s why there may be some well organized layout. In this method we problems to locate all the machines. Also estimated 800 sq m (40x20) which is quite big of In the SCHMIGALLA method we estimated 900 machines we used in our layouts are quite layout. There are some advantages to use ROC sq m (30x30) which is the big of layout. The expencive. In MST method we have some method such as: Better utilization of machines transportation path is also the longest path advantages such as: Total production time per can result consequently, A high degree of comparing to the other methods. unit is short, Simple production planning and flexibility exists relative to equipment or control systems are possible, Less space is manpower allocation for specific tasks… occupied by work in transit and for temporary storages…
COST COMPARISON
Comparing to other methods, in the MST method we have the lowest value
In the ROC method we have medium value (but quite big)
29
In the SCHMIGALLA method we have the highest cost
During the Factory Layout Planning and Optimization project, we’ve discovered that there cannot be only one best method. Each method has its own advantages and each production must be optimized individually. According to our project, we can think that MST is the best solution for us, but looking at shape of factory there is quite hard to plan long and narrow hall. So we choose ROC method because of the shortest long of transportation paths. A properly designed plant layout is an important source of competitive advantage. It can:
operate all cost,
provide fast delivery,
accommodate frequent new products,
produce many varied products,
produce high or low volume products,
produce at the highest quality level provide,
unique services or features.
30
