Layout optimization for production line using product lifecycle management

Suratman, Fatin Aqilah (2021) Layout optimization for production line using product lifecycle management. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Plant layout or facility layout is the process of designing and constructing workforce, material handling, and equipment systems. It encompasses determining the locations, sizes, and configurations of many tasks throughout the facility. It exemplifies a strategy for arranging, developing, or visualizing the desirable machinery and equipment in the most efficiently. Layout optimization comprises arranging items in the proper locations to facilitate future expansions in order to provide efficient material handling, ensure optimal space utilization, and an excellent work environment. Optimizing layout can increase productivity, product quality, and safety. This project is conducted in Prym Consumer Malaysia Sdn. Bhd. and Teaching Factory University Technical Malaysia Melaka (UTeM). By considering the current layout of the production line, the problem is that the total output of the circular knitting needle does not achieve the target. The aims of this research are to investigate the production line layout of the circular knitting needle packaging process, to simulate, and to propose the most optimum layouts using Product Lifecycle Management (PLM). PLM is broadly and widely used in modern manufacturing systems due to it can effectively manage a product across its lifecycles, from the very first idea until the disposal of the product. This project begins with record and analyze the packaging process of circular knitting needles by conducting time study. Then, analyze the initial layout of the production line for circular knitting needles packaging process. Following that, plan new layouts and simulate it. Tecnomatix Plant Simulation is used to create and simulate the layout. The most optimal layouts are proposed based on the simulation results. The optimal layouts have the highest daily throughput of 2602.01 and 6308.61. It is showed that optimal layout could increase the productivity of a company.

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