Factory Layout Research Articles

Application of a Hybrid Digital Twin Concept for Factory Layout Planning

Abstract As the modern society is in the middle of its fourth industrial revolution, many enabling technologies are now viable to use in an engineering context. Several of these technologies are mature and available off the shelf; however, in the industrial setting they are rather novel. Two of these are virtual reality (VR), which has grown immensely in the gaming sector, and 3-D imaging, which is commonly used in archeology and construction. This study presents lessons learned from combining these two technologies in an industrial context with the digital twin concept. Three industrial case studies have been performed, and several observations have been identified in all three aspects of sustainability. For example, improved solution fidelity at an early stage can be achieved by externalizing tacit knowledge, and multiple issues during planning and installation phases have been avoided by utilizing the hybrid digital twin models. This type of digital twin enables highly detailed production system access, enabling engineering abilities from anywhere, anytime. Furthermore, the model becomes a powerful communication tool, which has reduced the resistance to workplace changes, as stakeholders lacking computer-aided design (CAD) knowledge can be involved in the change process. The highly detailed models have also allowed more focus to be put on safety and regulations, as these aspects naturally are more suited to experience in immersive VR. In conclusion, the hybrid digital twin concept developed in this study is a promising tool for decision makers and stakeholders alike, bound to benefit those who use it in all three aspects of sustainability.

Design of Manufacturing Lines Using the Reconfigurability Principle

Nowadays, many factories face changes on the global market and manufacturing is unpredictable. This fact creates a demand for developing new concepts of the factory which can represent a solution to these changes. This study presents a way for designing these new factory concepts, particularly a concept of the reconfigurable manufacturing lines. The methodology in this study uses characteristics of reconfigurable manufacturing systems for developing an algorithm for designing the basic factory layout. The methodology also combines classical math operations for designing the production layout with such approaches as simulation, cluster analysis, and LCS algorithm. This combination method with LCS algorithm and an entirely different approach to the design of the manufacturing line, has not yet been used. The accuracy of this methodology is then verified through the results of the complete algorithm containing these features. The main purpose of this study was to find new approaches to designing the reconfigurable factory layout. This article is presenting new ways that differ from the classical design method. The article suggests the new way is possible and the new systems also need new ways for designing and planning.

Redesign Layout Planning of Raw Material Area and Production Area Using Systematic Layout Planning (SLP) Methods (Case Study of CV Oto Boga Jaya)

CV Oto Boga Jaya (Oto Bento) is one of the largest industries which is producing Japanese food that is located in Bogor City and has many franchise partners throughout Indonesia. CV Oto Boga Jaya has the most significant problem and complained by most employees and operators (interview results) is a matter of factory layout between the raw material warehouse and the production area where the position of the two departments has an excess of more than 29 meters and takes time more than 10 minutes for one move. Therefore, researcher conducted observations and data processing with systematic layout planning (SLP) methods to design a new factory layout for CV Oto Boga Jaya. The processed data is the Operation Product Chart (OPC) data by selecting the product that has the highest and longest production process named shrimp roll, routing sheet, material handling costs, and initial layout as a reference. Then after conducting the research, the results obtained are in the form of 2 alternative layouts with distances and positions of different departments that have been processed in the FTC, ARC, ARD, AAD. The results of this study were chosen alternative layout 2, because it has shorter inter-departmental distances, a more orderly production / administration process, and fewer room intersections compared to alternative layout 1.

USULAN PERBAIKAN TATA LETAK FASILITAS PRODUKSI INDUSTRI KOPI STUDI KASUS CV. TRI ANOM AGROTEKTUR

Industrial layout is one of the important factors that affecting the efficiency of the production operation process, which can be seen from the material movement activities to be processed into products. CV. Tri Anom Agrotektur manages the coffee industry which is divided into 2 activity sectors, namely the upstream and downstream sectors. This study designed a proposal to improve the factory layout of the company’s upstream sector using qualitative methods and direct interviews with factory employees. In determining the layout improvement of the industry, it is necessary to first identify the production process, using the Process Flow Diagram and Process Flow Map. The data processing methods used are: Activity Relationship Chart (ARC), Activity Relationship Diagram (ARD), and Activity Allocation Diagram (AAD). Total area of the factory building is ± 1.072 m2, while the proposed total area of the building based on the area of the machine, the area of the employee’s movement and the additional area of production support room is ± 833 m2. The total proposed rooms are 23 rooms. Proposed improvements to the industrial layout can be use as company reference that is expected to increase productivity and reduce production costs

Natural Virtual Reality User Interface to Define Assembly Sequences for Digital Human Models

Digital human models (DHMs) are virtual representations of human beings. They are used to conduct, among other things, ergonomic assessments in factory layout planning. DHM software tools are challenging in their use and thus require a high amount of training for engineers. In this paper, we present a virtual reality (VR) application that enables engineers to work with DHMs easily. Since VR systems with head-mounted displays (HMDs) are less expensive than CAVE systems, HMDs can be integrated more extensively into the product development process. Our application provides a reality-based interface and allows users to conduct an assembly task in VR and thus to manipulate the virtual scene with their real hands. These manipulations are used as input for the DHM to simulate, on that basis, human ergonomics. Therefore, we introduce a software and hardware architecture, the VATS (virtual action tracking system). This paper furthermore presents the results of a user study in which the VATS was compared to the existing WIMP (Windows, Icons, Menus and Pointer) interface. The results show that the VATS system enables users to conduct tasks in a significantly faster way.

Cabin Placement Layout Optimisation Based on Systematic Layout Planning and Genetic Algorithm

Abstract Cabin placement layout is an important part of ship cabin layout design. A good cabin placement layout can improve the efficiency of the ship’s cabin arrangement. However, optimisation of the layout of cabin placement is not widely studied and more often relies on the experience of the staff. Thus, a novel methodology combining systematic layout planning and a genetic algorithm to optimise the cabin placement is presented in this paper. First key elements are converted by a systematic planning method that is often applied in factory layout, and a preliminary cabin placement layout model is established according to these key elements. Then the circulation strength and adjacency strength are taken as sub-objectives to establish a mathematical model, and an improved genetic algorithm is used to optimise the model. The result of the optimisation is compared with the initial schemes to verify the validity of the algorithm. Finally, the human factors are introduced according to the actual situation. The AHP method is used to select the layout scheme of the cabin that is most likely to be applied in the actual cabin layout.

Enumerating Grid Layouts of Graphs

We study algorithms that generate layouts of graphs with $n$ vertices in a square grid with $\nu$ points, where adjacent vertices in the graph are also close in the grid. The problem is motivated by graph drawing and factory layout planning. In the latter application, vertices represent machines, and edges join machines that should be placed next to each other. Graphs admitting a grid layout where all edges have unit length are known as partial grid graphs. Their recognition is NP-hard already in very restricted cases. However, the moderate number of machines in practical instances suggests the use of exact algorithms that may even enumerate the possible layouts to choose from. We start with an elementary $n^{O(\sqrt{n})}$ time algorithm, but then we argue that even simpler exponential branching algorithms are more usable for practical sizes $n$, although being asymptotically worse. One algorithm interpolates between obvious $O^*(3^n)$ time and $O^*(4^{\nu})$ time for graphs with many small connected components. It can be modified in order to accommodate also a limited number of edges that can exceed unit length. Next we show that connected graphs have at most $2.9241^n$ grid layouts that can also be efficiently enumerated. An $O^*(2.6458^n)$ time branching algorithm solves the recognition problem, or yields a succinct enumeration of layouts with some surcharge on the time bound. In terms of the grid size we get a slightly better $O^*(2.6208^{\nu})$ time bound. Moreover, if we can identify a subgraph that is rigid, i.e., admits only one layout up to congruence, then all possible layouts of the entire graph are extensions of this unique layout, such that the combinatorial explosion is then confined to the rest of the graph. Therefore we also propose heuristic methods for finding certain types of large rigid subgraphs. The formulations of these results is more technical, however, the proposed method iteratively generates certain rigid subgraphs from smaller ones.

The Simulation Model of Iron Sponge Plant Layout for the Defense Industry Based on Industry 4.0 Model

The Industry 4.0 is a change in the perspective of how to view an industry based on the resources owned, to operate according to needs. The sponge iron industry is a raw material industry to support the steel industry which is intended as material for shipbuilding and combat vehicles used by the Indonesian National Millitary. It is necessary to plan and design a sponge iron plant with an Industrial 4.0 model. The implementation of the Industry 4.0 model aims to optimize the operational needs of the plant, especially the sponge iron plant, which is relatively rare in Indonesia. The concept of a factory layout (cellular layout, modular layout), the concept of lean manufacturing, as well as the concepts and principles of the smart factory (Cyber-Physical Systems) are concepts that will be applied in the planning and design of the Industrial 4.0 sponge iron plant layout. In order to produce an optimal layout, a simulation model using FlexSim 2018 Software and layout optimization is used the Computerized Relative Allocation of Facilities Technique (CRAFT) algorithm with the help of CRAFT Software Integrated Microsoft Excel 2019.

Interaction design for multi-user virtual reality systems: An automotive case study

Virtual reality (VR) technology have become ever matured today. Various research and practice have demonstrated the potential benefits of using VR in different application area of manufacturing, such as in factory layout planning, product design, training, etc. However, along with the new possibilities brought by VR, comes with the new ways for users to communicate with the computer system. The human computer interaction design for these VR systems becomes pivotal to the smooth integration. In this paper, it reports the study that investigates interaction design strategies for the multi-user VR system used in manufacturing context though an automotive case study.

Concept for the comparison of intralogistics designs with real factory layout using augmented reality, SLAM and marker-based tracking

In the automotive industry, the intralogistics planning faces the problem of matching the planning data with the current conditions in the assembly hall. The large variety of parts leads to a constantly changing production. Based on this, we establish an approach for the comparison using augmented reality (AR) and simultaneous localization and mapping (SLAM). The use of SLAM enables the consistent application of AR in an assembly hall. Based on this, the objective of this article is to visualize 3D objects from the corresponding CAD planning tool in the real factory and thus the comparison of the intralogistics design with the real factory is possible due to AR. Nevertheless, there was a lack of practical implementations in intralogistics and therefore the concept is evaluated by two prototypical solutions. The first one is implemented on an iPhone 7 using SLAM. The second prototype is developed on a HoloLens 2 and is based on a hybrid tracking solution, SLAM and marker tracking.

New Approach for Digital Factory Using Virtual Reality Technology

The digital factory represents an indispensable method for factory layout planning. Based on digital factory methods numerous tools for layout planning have been developed in the last years, which enable the space organization of the assets of a factory based on 2D/3D data. Such tools have a difficulty to show the whole layout plan and to interact and to handle with the factory assets in intuitive and realistic manner. This paper presents and discuss a VR-based approach for efficient factory planning. This approach enables fully immersion in the virtual environment represented factory and an intuitive interaction with factory equipment. Hence, the layout planning can be assessed in real time regarding e.g. efficiency of surface use, martial flow, ergonomics. The presented approach has been designed based on the many years experience of the author as digital factory engineer in the industry and based on intensive discussion with industry experts.

Tata Ruang dan Perkembangan Kompleks Pabrik Gula Tanjung Tirto Tahun 1920-1944, Kabupaten Sleman

The Tanjung Tirto sugar factory was one of 18 sugar factories that had been established in Yogyakarta during the Dutch East Indies administration. This factory was built in 1874 and was destroyed in the 1940s. The layout and development of the sugar factory from 1920-1940 were discussed in this study. Based on field observations, the emplacement of the factory buildings was not complete and only left a few housing buildings for the former factory employees. In addition, reconstruction through an old map is a way to find out the location and development of this factory. This study is important considering the lack of sugar factories in Yogyakarta which are the object of archeological research studies.

High Reliability, Low Latency and Cost Effective Network Planning for Industrial Wireless Mesh Networks

In this paper, we study high reliability, low latency and cost effective network planning for industrial wireless mesh networks. Based on the requirements of routing reliability, minimum end-to-end delay and reduced deployment cost in wireless mesh networks, such as WirelessHART network, we propose three network planning approaches following the principles of the shortest hops, the least routers and balance of the shortest hops and the least routers, respectively. We then implement the proposed algorithms respectively to generate the network deployment for a given factory layout. Simulation results show that there exists a performance trade-off between these three algorithms. The proposed algorithms have also been implemented and validated in an NS-2 WirelessHART network simulator.

Optimal Exit Configuration of Factory Layout for a Safer Emergency Evacuation using Crowd Simulation Model and Multi-Objective Artificial Bee Colony Optimization

This work aims at providing a systematic method in producing a safer and optimal factory layout based on a crowd simulation model and the multi-objective artificial bee colony optimization technique. Apart, from ensuring the efficiency of manufacturing processes in planning a factory layout, it is also important that the safety aspect is taken into account. A factory is usually a closed working area consisting of machines, equipment, assembly lines as well as individual working space and other departments within the factory. In this environment, workers move around in the factory to perform different activities, and hence highly complex crowd behaviours that are influenced by the physical, social and psychological factors of the crowd might take place. Therefore, the layout of the factory must be carefully designed so that efficient movements of people can be obtained. Furthermore, during emergency situations that require efficient evacuation of workers from the factory building, a good factory layout will prevent or minimize the possibility of injuries during the evacuation process. This will reduce the evacuation egress time, which is the quantity used to evaluate the evacuation efficiency and the building’s level of safety. One of the techniques to assess the evacuation efficiency of a particular space configuration is by using the crowd simulation model. Recent evidences suggest that the representation of crowd dynamics using a simulation model is useful, where experiments with real humans are too dangerous and not practical to be implemented. This work explains the method to provide optimal exit door configurations for a factory layout by analyzing the crowd evacuation time and the discomfort level, where the proposed optimum exit configurations will be compared with the original configuration for a better evacuation efficiency.

Determinants in Developing a Learning Factory In Higher Educational Institution

Manufacturing education will be faced with major challenges in the years to come. Due to the rapid changes of products and production systems, students need to be more exposed to existing and advanced methods. The purpose of this study is to examine a student’s perception toward determinants to be considered in developing a learning factory that can provide an authentic industrial working experience in the manufacturing and production sector in the higher educational institution that they are enrolled. An appropriate learning factory experience is expected to improve students’ competencies and skills. The study used quantitative method to collect the student perception on determinants of learning factory development. Two hundred questionnaires have been distributed among students of Faculty Industrial Technology Management (FIM) in Universiti Malaysia Pahang (UMP). The results of survey revealed that the most important determinant in developing the learning factory are the learning factory layout design, equipment capability, safety and the effectiveness of assessment given related with theory knowledge that has been learnt. This result is useful for the management of Faculty of Industrial Technology Management to improve their decisionmaking process in enhancing the learning factory in UMP for the future development.

PERANCANGAN ULANG TATA LETAK FASILITAS DALAM MENINGKATKAN EFEKTIVITAS PRODUKSI (STUDI OBSERVASI PT. KALIMANTAN CONCRETE ENGGINERRING)

Industry is an economic activity that processes raw materials, raw materials, semi-finished goods or finished goods into high-quality goods in use, including engineering and engineering activities. Thus, industry is part of the production process. Industrial materials are taken directly or indirectly, then processed, resulting in more valuable goods for the community. In an industry not only concerns how much investment should be invested, production procedures and marketing of products but also requires the planning of facilities that include the location planning facility and facility design. Facility design includes facility system design, factory layout and material handling system (material transfer). (Wikipedia Bahasa Indonesia). In its current development PT. Kalimantan Concrete Engineering extends production land by purchasing a plot of land adjacent to the current production site, but it has not been enabled yet, in addition to the placement of U-dith and Box Culvert production which have not been placed in accordance with its area in the current name still in place at road front office and other areas that are still far apart. In accordance with the above explanation, we can know that the importance of an effective and efficient facility layout planning where it is in need in material handling arrangements, time efficiency, and the flow of work mobility. So this research is expected to be able to provide trobosan in the relationship layout facilities and improve the effectiveness of work better. Keywords: PT. Kalimantan Concrete Engineering, ARC, MHPS, Efektivitas

Methodology and decentralised control of modularised changeable conveyor logistics system

ABSTRACTTo comply with the trend of customised production, this paper proposes a novel methodology for a changeable logistics system on certain factory scenes. By modularising the traditional conveyor belt system and applying decentralised control to each module, the changeable conveyor system can quickly reassemble itself for different logistics routes and thus react to the changing requirements of new production plans. The logistics route transformation is organised in two stages while reassembling. First, the modules calculate their paths on their own towards the assigned positions using a modified Rapid-exploring Random Tree (RRT) algorithm with the introduction of orientation factor (α-factor) to increase path smoothness; then a sensor-based Artificial Potential Field (APF) algorithm is applied for real-time collision avoidance with the sensor orientation and data weight being specially arranged. Through these two stages, the proposed system can flexibly react to changing logistics demands and form various logistics routes in the factory layout according to customised production requirements. Simulations and comparisons are given to illustrate the performances of the method.

An Augmented Reality approach to factory layout design embedding operation simulation

The subject of this work is layout planning of machinery, especially for Flexible Manufacturing Systems (FMS), using Augmented Reality tools. The goal is for the user to evaluate suggested layouts by taking into account non-measurable factors, such as operator experience, empirical or non-tacit knowledge and on-site impression. By reference to existing machinery (in the case study: CNC lathe and an industrial robot) the missing elements of a complete FMS cell (conveyor belts, automatic storage and retrieval system, other robots and CNC machines etc.) are super-imposed. The functional connection is enabled between the collaborating real-physical and the virtual machinery of the layout in the most convincing way, i.e., by simulation of the full production process involving movement, manipulation and processing of parts by real and virtual equipment in parallel and serial co-existence. This involves predefined scenarios that can be experienced exploiting alternative equipment in the same application and alternative layouts assessed in analogous applications. Static and dynamic simulation of the manufacturing cell offers the possibility of extensive analysis of the selected layout by walk-through navigation. The application is implemented in ARKit™ API tool and Unity3D™.

Development of virtual reality support to factory layout planning

Virtual reality (VR) technology has become ever mature today with affordable and yet powerful hardware. In the manufacturing industry, there is a growing interest of adopting VR to improve existing work procedures. Factory layout planning (FLP) is a long standing area in production engineering that sees great potentials of VR integration. Virtual reality supported layout planning (VLP) is gaining wider attention in research and practice as the virtual environment allows designers to test out “what if” scenarios in relative ease. However, previous research of VLP mostly focus on general layout planning but not the detailed level planning. Also, it is reported that the virtual modeling process is time-consuming and costly. In this study, we propose a point cloud based virtual factory modelling approach for the VLP tasks. It incorporates point cloud representation of physical environment with CAD data to model the virtual factory with the aims of simplifying the modelling process and improving decision-making for the VLP tasks. The proposed approach is exemplified and refined through three industrial cases. The implementations and results of the cases are highlighted and discussed in details. At the end, a general guidance for VLP is extracted and presented for future point cloud based VR support in FLP tasks.

Integration of LiFi Technology in an Industry 4.0 Learning Factory

Abstract We are currently developing a modular and decentralized learning factory to demonstrate Industry 4.0 and Logistics 4.0 scenarios to both, students and employees from the companies. The factory shall allow the setup and evaluation of any preferred factory layout. One major challenge is the design of an appropriate strategy for communication between the factory modules and the identification of adequate communication technologies. There are two main requirements, which we consider for the communication design. First, the communication shall be wireless in order to reduce the effort for changing the factory structure. Second, the communication strategy shall allow an easy identification of the current factory layout and the interconnection of factory resources. According to our current state of knowledge, we believe that LiFi (Light Fidelity) is a suitable technology to fulfill these requirements. In the paper, we discuss the benefits and drawbacks of LiFi as communication technology and present a concept for the integration of LiFi in our learning factory.