Abstract
Facility layout planning plays a pivotal role in manufacturing system design, impacting vital metrics such as lead time, handling costs, and space optimization. While a significant portion of research has been invested in refining existing facility layouts, there is a noticeable research gap in devising optimized layouts for new establishments, especially in the value-added wood products domain. Addressing this lacuna, this research focused on designing an efficient department-level layout for a wooden cable drums manufacturing facility in an area of 4150 m2. This facility included both office and production areas. The investigative process was segmented into four distinct phases: Deciding the strategic positioning of the facility on the available plot, defining the functional and spatial requirements for each department, establishing the intricate relationship dynamics between these individual units, and rigorously documenting the most optimal department-level facility layout. For precision in layout creation, the ALDEP algorithm was employed, which was further visualized to offer a comprehensive three-dimensional representation. The final layout seamlessly organized seven departments within the 1st Floor Office Area, eight in the 2nd Floor Office Area, and thirteen within the Production Floor. Efficiency evaluation of these areas yielded scores of -811, 184, and -318, respectively. Conclusively, this research furnished actionable insights for manufacturers within the wood products sector and was expected to be an invaluable reference for academics delving into facility planning and value-added wood products manufacturing.
References
- Ak, R., 2009. Investigation of Workplace Organization Algorithms and a Factory Application, Master's Thesis, Istanbul Technical University, Institute of Science and Technology, Istanbul.
- Amar, C., Onkar, S., Allied Market Research 2020. Cable Drum Market Size, Share, Competitive Landscape and Trend Analysis Report by Material and Mechanism: Global Opportunity Analysis and Industry Forecast, 2019-2026, United Kingdom, https://www.alliedmarketresearch.com/cable-drum-market, Accessed: 04.02.2024. Andryzio, A., Mustofa, F. H., Fitria, L., 2014. Proposed Facility Layout Design Using the Method Automated Layout Desing Program (ALDEP) DI CV. Kawani Tekno Nusantara. Jurnal Online Institut Teknologi Nasional, 2(4). https://ejurnal.itenas.ac.id/index.php/rekaintegra/article/view/644
- Budianto, F., Halim, J., Christine Sembiring, A., 2020. Redesigning Furniture Production Floors Using Systematic Layout Planning and ALDEP Method to Minimize Material Handling Costs. 2020 3rd International Conference on Mechanical, Electronics, Computer, and Industrial Technology (MECnIT), 25—27 June, Medan, Indonesia, pp. 84–90. https://doi.org/ 10.1109/MECnIT48290.2020.9166613
- Burggräf, P., Adlon, T., Hahn, V., Schulz-Isenbeck, T., 2021. Fields of Action Towards Automated Facility Layout Design and Optimization in Factory Planning – A Systematic Literature Review. CIRP Journal of Manufacturing Science and Technology, 35: 864–871. https://doi.org/10.1016/j.cirpj.2021.09.013
- Deshpande, V., Patil, N. D., Baviskar, V., Gandhi, J., 2016. Plant Layout Optimization using CRAFT and ALDEP Methodology. Productivity Journal by National Productivity Council, 57(1): 32–42. https://www.researchgate.net/publication/318743771
- Eryiğit, M., 2000. Factory and Workplace Organization, Master's Thesis, Abant İzzet Baysal University, Institute of Social Sciences, Bolu.
- Gutta, P. R., Chinthala, V. S., Manchoju, R. V., Charan MVN, V., Purohit, R., 2018. A Review On Facility Layout Design Of An Automated Guided Vehicle In Flexible Manufacturing System. Materials Today: Proceedings, 5(2): 3981–3986. https://doi.org/10.1016/j.matpr.2017.11.656
- Lee, A., 2013. Cost-Optimized Warehouse Storage Type Allocations. Master’s Thesis, University of Southern California, Los Angeles, USA
- Özden, K., 2016. Facility Planning: Workplace, Factory Design and Layout, Papatya Publishing Education, Istanbul.
- Prasad, N. H., Rajyalakshmi, G., Reddy, A. S., 2014. A Typical Manufacturing Plant Layout Design Using CRAFT Algorithm. Procedia Engineering, 97: 1808–1814. https://doi.org/10.1016/j.proeng.2014.12.334
- Seehof, J. M., Evans, W. O., Friederichs, J. W., Quigley, J. J., 1966. Automated Facilities Layout Programs. A.C.M. National Meeting, Rochester, Minnesota, pp. 191–199. https://doi.org/doi/pdf/ 10.1145/800256.810696
- Suhardini, D., Rahmawati, S. D., 2019. Design and Improvement Layout of a Production Floor Using Automated Layout Design Program (ALDEP) and CRAFT Algorithm at CV. Aji Jaya Mandiri. IOP Conference Series: Materials Science and Engineering, 27-29 November, Makasar, Soult Sulawesi, Indonesia. https://doi.org/10.1088/1757-899X/528/1/012062
- Suhardini, D., Septiani, W., Fauziah, S., 2017. Design and Simulation Plant Layout Using Systematic Layout Planning. IOP Conference Series: Materials Science and Engineering, 7-9 November, Tanjung Pandan-Belitung, Indonesia, https://doi.org/10.1088/1757-899X/277/1/012051
- Sydor, M., Wołpiuk, M., Surowaniec, M., Rogoziński, T., 2017. Issues of Wooden Cable Drums Production Technology. Annals of WarsawUniversity of Life Sciences, 100: 11–17. https://journals. indexcopernicus.com/api/file/viewByFileId/349617
- Tambunan, M., Ginting, E., Sari, R. M., 2018. Production Facility Layout by Comparing Moment Displacement Using BLOCPLAN and ALDEP Algorithms. IOP Conference Series: Materials Science and Engineering, 7-8 September, Indonesia, https://doi.org/ 10.1088/1757-899X/309/1/012032
- Tarigan, U., Simbolon, R., Sembiring, M. T., Tarigan, U. P. P., Sembiring, N., Tarigan, I. R., 2019. Perancangan Ulang dan Simulasi Tata Letak Fasilitas Produksi Gripper Rubber Seal dengan Menggunakan Algoritma Corelap, Aldep, dan Flexsim. Jurnal Sistem Teknik Industri, 21(1). https://doi.org/10.32734/jsti.v21i1.905
- Türkmen, N. A., Oğulata, S. N., 2008. Hospital Workflow and Layout Assessment. Master Thesis, Çukurova University, Institute of Science and Technology, Adana.
Abstract
Tesis yerleşimi planlaması, üretim sistemi tasarımında önemli bir rol oynamaktadır ve teslimat süresi, taşıma maliyetleri ve alan optimizasyonu gibi önemli metrikleri etkilemektedir. Mevcut tesis yerleşimlerini iyileştirmek için önemli sayıda araştırma yapılmış olsa da özellikle katma değerli orman ürünleri alanında yeni kuruluşlar için optimize edilmiş yerleşimler tasarlama konusunda belirgin bir araştırma açığı bulunmaktadır. Bu çalışma kapsamında 4150 m2'lik bir alana sahip ahşap kablo makaraları üretim tesisinde bölümler düzeyinde verimli bir yerleşim planı tasarlanmasına odaklanılmıştır. Yerleşim planlaması gerçekleştirilen tesis hem ofis hem de üretim alanlarını içermektedir. İnceleme süreci dört farklı aşamaya ayrılmıştır: Tesise uygun arazi üzerinde stratejik konumun belirlenmesi, her bölüm için işlevsel ve mekânsal gereksinimlerin tanımlanması, bu ayrışık birimler arasındaki karmaşık ilişki dinamiklerinin oluşturulması ve en uygun tesis yerleşiminin bölüm düzeyinde titizlikle oluşturulması. Tesis yerleşim planının isabetli bir şekilde gerçekleştirilmesi için ALDEP algoritması kullanılmış olup, bu algoritma sonucunda elde edilen sonuçlar daha sonra kapsamlı üç boyutlu temsiller sunacak şekilde görselleştirilmiştir. Nihai tesis yerleşim planında 1. Kat Ofis Alanı'nda yedi departman, 2. Kat Ofis Alanı'nda sekiz departman ve Üretim Katı'nda on üç departman sorunsuz bir şekilde organize edilmiştir. Bu alanların verimlilik değerlendirmesi sırasıyla -811, 184 ve -318 skorlarını almıştır. Sonuç olarak, bu araştırma, orman ürünleri sektöründeki üreticiler için eyleme dönüştürülebilir içgörüler sunmuştur ve tesis planlaması ve katma değerli orman ürünleri üretimi alanlarında araştırma yapan akademisyenler için değerli bir referans olması beklenmektedir.
References
- Ak, R., 2009. Investigation of Workplace Organization Algorithms and a Factory Application, Master's Thesis, Istanbul Technical University, Institute of Science and Technology, Istanbul.
- Amar, C., Onkar, S., Allied Market Research 2020. Cable Drum Market Size, Share, Competitive Landscape and Trend Analysis Report by Material and Mechanism: Global Opportunity Analysis and Industry Forecast, 2019-2026, United Kingdom, https://www.alliedmarketresearch.com/cable-drum-market, Accessed: 04.02.2024. Andryzio, A., Mustofa, F. H., Fitria, L., 2014. Proposed Facility Layout Design Using the Method Automated Layout Desing Program (ALDEP) DI CV. Kawani Tekno Nusantara. Jurnal Online Institut Teknologi Nasional, 2(4). https://ejurnal.itenas.ac.id/index.php/rekaintegra/article/view/644
- Budianto, F., Halim, J., Christine Sembiring, A., 2020. Redesigning Furniture Production Floors Using Systematic Layout Planning and ALDEP Method to Minimize Material Handling Costs. 2020 3rd International Conference on Mechanical, Electronics, Computer, and Industrial Technology (MECnIT), 25—27 June, Medan, Indonesia, pp. 84–90. https://doi.org/ 10.1109/MECnIT48290.2020.9166613
- Burggräf, P., Adlon, T., Hahn, V., Schulz-Isenbeck, T., 2021. Fields of Action Towards Automated Facility Layout Design and Optimization in Factory Planning – A Systematic Literature Review. CIRP Journal of Manufacturing Science and Technology, 35: 864–871. https://doi.org/10.1016/j.cirpj.2021.09.013
- Deshpande, V., Patil, N. D., Baviskar, V., Gandhi, J., 2016. Plant Layout Optimization using CRAFT and ALDEP Methodology. Productivity Journal by National Productivity Council, 57(1): 32–42. https://www.researchgate.net/publication/318743771
- Eryiğit, M., 2000. Factory and Workplace Organization, Master's Thesis, Abant İzzet Baysal University, Institute of Social Sciences, Bolu.
- Gutta, P. R., Chinthala, V. S., Manchoju, R. V., Charan MVN, V., Purohit, R., 2018. A Review On Facility Layout Design Of An Automated Guided Vehicle In Flexible Manufacturing System. Materials Today: Proceedings, 5(2): 3981–3986. https://doi.org/10.1016/j.matpr.2017.11.656
- Lee, A., 2013. Cost-Optimized Warehouse Storage Type Allocations. Master’s Thesis, University of Southern California, Los Angeles, USA
- Özden, K., 2016. Facility Planning: Workplace, Factory Design and Layout, Papatya Publishing Education, Istanbul.
- Prasad, N. H., Rajyalakshmi, G., Reddy, A. S., 2014. A Typical Manufacturing Plant Layout Design Using CRAFT Algorithm. Procedia Engineering, 97: 1808–1814. https://doi.org/10.1016/j.proeng.2014.12.334
- Seehof, J. M., Evans, W. O., Friederichs, J. W., Quigley, J. J., 1966. Automated Facilities Layout Programs. A.C.M. National Meeting, Rochester, Minnesota, pp. 191–199. https://doi.org/doi/pdf/ 10.1145/800256.810696
- Suhardini, D., Rahmawati, S. D., 2019. Design and Improvement Layout of a Production Floor Using Automated Layout Design Program (ALDEP) and CRAFT Algorithm at CV. Aji Jaya Mandiri. IOP Conference Series: Materials Science and Engineering, 27-29 November, Makasar, Soult Sulawesi, Indonesia. https://doi.org/10.1088/1757-899X/528/1/012062
- Suhardini, D., Septiani, W., Fauziah, S., 2017. Design and Simulation Plant Layout Using Systematic Layout Planning. IOP Conference Series: Materials Science and Engineering, 7-9 November, Tanjung Pandan-Belitung, Indonesia, https://doi.org/10.1088/1757-899X/277/1/012051
- Sydor, M., Wołpiuk, M., Surowaniec, M., Rogoziński, T., 2017. Issues of Wooden Cable Drums Production Technology. Annals of WarsawUniversity of Life Sciences, 100: 11–17. https://journals. indexcopernicus.com/api/file/viewByFileId/349617
- Tambunan, M., Ginting, E., Sari, R. M., 2018. Production Facility Layout by Comparing Moment Displacement Using BLOCPLAN and ALDEP Algorithms. IOP Conference Series: Materials Science and Engineering, 7-8 September, Indonesia, https://doi.org/ 10.1088/1757-899X/309/1/012032
- Tarigan, U., Simbolon, R., Sembiring, M. T., Tarigan, U. P. P., Sembiring, N., Tarigan, I. R., 2019. Perancangan Ulang dan Simulasi Tata Letak Fasilitas Produksi Gripper Rubber Seal dengan Menggunakan Algoritma Corelap, Aldep, dan Flexsim. Jurnal Sistem Teknik Industri, 21(1). https://doi.org/10.32734/jsti.v21i1.905
- Türkmen, N. A., Oğulata, S. N., 2008. Hospital Workflow and Layout Assessment. Master Thesis, Çukurova University, Institute of Science and Technology, Adana.
Details
| Primary Language | English |
|---|---|
| Subjects | Forestry Sciences (Other) |
| Journal Section | Orijinal Araştırma Makalesi |
| Authors | |
| Publication Date | March 30, 2024 |
| Acceptance Date | February 16, 2024 |
| Published in Issue | Year 2024 |