Layout analysis and improvement in a manufacturing industry : a case study

Abdullah Kamil, Puteri Eliani Fikri (2017) Layout analysis and improvement in a manufacturing industry : a case study. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The objective of this study was to analyse the production floor layout of Winco Precision Engineering and to redesign the production line layout to maximize the utilization of manpower and machines in this company. This study was conducted at Winco Precision Engineering, a manufacturing company located in Bukit Rambai, Melaka. This company was originally located in Taman Perindustrian Cheng and will be moving to a new factory in Bukit Rambai. They had been using the same layout for the past 13 years and with the relocation of the factory, they wanted to take the opportunity to use a new layout which could optimize the utilization of their manpower and machines. The current layout can be seen to be having high cross over frequency for Shafts and Bearings products between two buildings. There was high flow intensity between machines which have high interrelationship. This leaded to high travelling distance and time. Two alternatives layout were proposed using the analysis of product routing and machine part matrix. The proposed alternative layout involves grouping the machines that involves in certain products in one cell. The proposed layouts were evaluated in term of total travel distance, total travel time, total travel cost, number of cross-over, output, average resource utilization, total average WIP level, total average waiting time and total time spent in the system.

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