Plant Layout Optimization in Steel Forging Industry by CORELAP Algorithm

Abstract

Objectives: The productivity problem encountered by a steel forging industry owing to its capacity enhancement has been bated for this research work. The study focused to identify a solution by optimizing the material flow in between the critical machines through the radical redesign of the plant layout. Methods: The plant layout determines the way in which the materials flow through the operation. Analysis of the layout data has done with relationship chart and closeness rating. The equipment for manufacturing was counted in terms of the direction of material flow and the time taken for the production process. The operation process chart, material flow pattern and activity relationship chart have been used in layout analysis through Computerized Relationship Layout Planning (CORELAP) method. It optimizes the material movement between the equipment and identifies the relative position of the various machineries in the processing area. A new model has been developed by CORELAP and simulation has done using the software Arena. Findings: The performance loss in the material flow pattern has been identified in the forging section of the plant. On the analysis with relationship chart and closeness rating, it is identified and this is happened with the extra time taken for the material flow by the imprecise positions of machines. The work flow pattern in the forging section is quite longer and unnecessary material transportation occurred there. Fifteen machines were relocated and optimized the production flow with CORELAP algorithm. The simulation study has conducted using Arena and the value-added time taken to produce each product in dissimilar machines in the modified layout is identified. Novelty/Improvement: The modified layout delivered a value addition in material flow pattern and shows an estimated improvement in productivity value of 7.98 percentages.