Material Flow Map and Layout Optimization: XVI Summer School "Francesco Turco" Industrial Mechanical Plants - SSD ING-IND/17 action plan and software validation “BREAKING DOWN THE BARRIERS BETWEEN RESEARCH AND INDUSTRY" Material Flow Map and Layout Optimization: action plan and software validation action plan and software validation Domenico Falcone, Alessandro Silvestri, Vincenzo Duraccio, Gianpaolo Di Bona University of Cassino - Faculty of Engineering [email protected], [email protected], [email protected], [email protected]Abano Terme (Padova, Italy) - 14-16 September 2011
Transcript
Material Flow Map and Layout Optimization:
XVI Summer School "Francesco Turco"Industrial Mechanical Plants - SSD ING-IND/17paction plan and software validation
“BREAKING DOWN THE BARRIERS BETWEEN RESEARCH AND INDUSTRY"
Material Flow Map and Layout Optimization: action plan and software validationaction plan and software validation
Domenico Falcone, Alessandro Silvestri, Vincenzo Duraccio, Gianpaolo Di Bona
Domenico Falcone, Alessandro Silvestri, Vincenzo Duraccio, Gianpaolo Di BonaXVI Summer School "Francesco Turco“ - Industrial Mechanical Plants - SSD ING-IND/17
Abano Terme (Padova, Italy) - 14-16 September 2011
Material Flow Map and Layout Optimization: p
action plan and software validation
Presentation of the research groupPresentation of the research group
Definition of Goals
Traditional tools for the layout study
Case Study
New integrated tool for the layout study
Domenico Falcone, Alessandro Silvestri, Vincenzo Duraccio, Gianpaolo Di BonaXVI Summer School "Francesco Turco“ - Industrial Mechanical Plants - SSD ING-IND/17
Conclusions
Material Flow Map and Layout Optimization: p
action plan and software validation
UNIVERSITY OF CASSINO
DEPARTMENT SCIENTIFICFIELD
FACULTY OF ENGINEERING
DIMSATDepartment of Mechanism,
Structures and Environment
INDUSTRIAL MECHANICAL
PLANTSWe develop and deepen the scientific knowledge and skills about:
Structures and Environment(ANIMP)
• logistics and supply chain;• production planning;• maintenance;• statistical process control;• quality and safety.
Domenico Falcone, Alessandro Silvestri, Vincenzo Duraccio, Gianpaolo Di BonaXVI Summer School "Francesco Turco“ - Industrial Mechanical Plants - SSD ING-IND/17
Material Flow Map and Layout Optimization: p
action plan and software validation
The present work suggests the main steps to verify the layout of The present work suggests the main steps to verify the layout of an industrial plant in order to:
- improve material flow; - reduce production lead time;
optimize warehouse and workplace- optimize warehouse and workplace.
A new tool has been developed able to integrateA new tool has been developed, able to integrate different traditional instruments
Domenico Falcone, Alessandro Silvestri, Vincenzo Duraccio, Gianpaolo Di BonaXVI Summer School "Francesco Turco“ - Industrial Mechanical Plants - SSD ING-IND/17
Material Flow Map and Layout Optimization: p
action plan and software validation TRADITIONAL LAYOUT CONFIGURATIONS
Flow-shop Job-shop
INNOVATIVE LAYOUT CONFIGURATIONSINNOVATIVE LAYOUT CONFIGURATIONS(Flexible layout for different production combinations)
Distributed
Domenico Falcone, Alessandro Silvestri, Vincenzo Duraccio, Gianpaolo Di BonaXVI Summer School "Francesco Turco“ - Industrial Mechanical Plants - SSD ING-IND/17
Modular
Material Flow Map and Layout Optimization: p
action plan and software validation
Traditional tools:- Operation/Assembly process chart;
Multi product process chart;- Multi product process chart;- From-To Chart;
- Flow Value Analysis Software supports:Flow Value Analysis- Value Stream Mapping;
Domenico Falcone, Alessandro Silvestri, Vincenzo Duraccio, Gianpaolo Di BonaXVI Summer School "Francesco Turco“ - Industrial Mechanical Plants - SSD ING-IND/17
Materials Warehouse 1 140160
Material Flow Map and Layout Optimization: p
action plan and software validation
Integrated Toll: FDR Index
FDRi,j Index = Flow Intensity x Distance x Relation Judgment,j y gi,j: pair of workstations or department
FDR Indexes Evaluation for the major criticalitiesFDR Indexes Evaluation for the major criticalities
From To Product[FI x D]
Relation Judgment FDR
R M i l W h 1 D t t 1 0 75Raw Materials Warehouse 1 Department 1 258720 0,75 19404
Raw Materials Warehouse 1 Department 3276480
0,7520736
Acceptance Area Finished Products Warehouse 235200
0,255880
Acceptance Area Shipment Area 2 671040 0,25 16776
Domenico Falcone, Alessandro Silvestri, Vincenzo Duraccio, Gianpaolo Di BonaXVI Summer School "Francesco Turco“ - Industrial Mechanical Plants - SSD ING-IND/17
Material Flow Map and Layout Optimization: p
action plan and software validation
Case Study – Old and New Layout ComparisonNew Layout Configuration
Old Layout Configuration
Domenico Falcone, Alessandro Silvestri, Vincenzo Duraccio, Gianpaolo Di BonaXVI Summer School "Francesco Turco“ - Industrial Mechanical Plants - SSD ING-IND/17
Material Flow Map and Layout Optimization: p
action plan and software validation
Validation through CRAFT*New Layout Configuration
CRAFT Layout Configuration
Domenico Falcone, Alessandro Silvestri, Vincenzo Duraccio, Gianpaolo Di BonaXVI Summer School "Francesco Turco“ - Industrial Mechanical Plants - SSD ING-IND/17
*Opportunely adapted in order to consider FDR
Material Flow Map and Layout Optimization: p
action plan and software validation
The approach developed permits to reach many specific advantages for the company:advantages for the company:
- Average transportation time reduction: less 40,39%;Average transportation time reduction: less 40,39%; - Average path distance reduction: less 38,65%; - Annual transport cost reduction: less 48,65%.
General characteristics of the methodological approach suggested therefore possible adoption in different industrialsuggested, therefore possible adoption in different industrial plants and configurations
Domenico Falcone, Alessandro Silvestri, Vincenzo Duraccio, Gianpaolo Di BonaXVI Summer School "Francesco Turco“ - Industrial Mechanical Plants - SSD ING-IND/17
