Machine Layout Research Articles

Noise and frequency propagation in natural stone processing plants

In this study, 510 noise measurements recorded in eight natural stone processing plants operating in Sivas City, Turkey were evaluated and the noise levels and dominant frequency bands of 11 different processing machines used in these plants were determined. The daily equivalent noise level of all natural stone processing plants was around or above the exposure limit value (87 dBA) specified in relevant regulations. Considering the machines and plant environment, the frequency ranges for the highest noise levels were mostly between 630 Hz - 5000 Hz, centering around 3150 Hz. Variations in the noise level of the processing machines in separate plants where similar processes were carried out was primarily related to the plant size and machine layout, the number of machines operating simultaneously and the type of natural stone processed. While the difference between the noise levels of gangsaws, bridge cutting, ST cutting, head/side cutting, trimming, cement filling, slab polishing, narrow polishing, chamfering and splitting machines were statistically significant, aging machines generated similar noise levels.

Biomechanics‐based study of muscle activation under different driving conditions for Chinese percentiles

AbstractIn this paper, we determined the adjustment levels of the human–machine layout under the preferred driving posture for individuals with different body sizes. We also comparatively analyzed the maximum activation levels of various muscles under straight‐line driving and steering conditions. To increase the accuracy of the results, AnyBody biomechanics software was used to establish a human skeletal muscle mechanics model, which we analyzed for consistency with rig test results. The results showed that people with larger body sizes preferred a driving position with the seat reclined back. Steered driving was associated with a significant (p < .05) increase in the maximum activation of the wrist extensors, serratus anterior, deltoid, and triceps brachii, which are the main force‐generating muscle groups for steered driving, compared with straight driving. Moreover, the measured and simulated results of maximum muscle activation were relatively consistent, with the error between them within a 15% margin. In summary, this study explored the relationship between different driving conditions and preferred driving postures from a biomechanical perspective. A combined experimental and simulation approach was adopted to ensure the reliability of the findings. The insights from this study can inform ergonomic considerations for the comfort and health of Chinese drivers with varying physical characteristics.

Facility layout design improvement in bottled drinking water at teaching factory

The Bottled Drinking Water Teaching Factory (Tefa) at State Polytechnic of Jember (Polije) produces mineral water packaged in several sizes of bottles, glasses, and gallons. The efficiency and effectiveness of the bottled drinking water production process is influenced by the layout of production facilities. The mismatch of machine layout arrangement and the number of unused equipment causes material flow to be longer. This study aims to redesign the layout of the Tefa Bottled Drinking Water facility to maximize area utilization and reduce empty space. This research provides recommendations for facility layout improvements using the Systematic layout planning (SLP) method. Alternative designs were proposed and compared the performance of each design with the initial layout. The results of the proposed method’s distance processing affect the total material handling cost. The total distance of the proposed method facility is 11.7 meters while the distance of the current facility is 28.8 meters so that can save material handling costs by 59%.

Job Safety Analysis (JSA) of Work Accidents on Wood Work Machines in the Construction Workshop

This research was motivated by the occurrence of work accidents that occurred in wood construction workshops and also the magnitude of potential hazards that might cause work accidents. The purpose of this study is first; To reveal how many types of static machines there are in the wood construction workshop. Second; Reveal the forms of accidents that have the potential to occur in woodworking machines. Third; Conduct JSA on the form of potential hazards of work accidents that may occur in the use of wood work machines. This type of research is quantitative descriptive with a survey method using the Guttman scale which produces percentages. This research was conducted on lecturers of wood work practice courses along with technicians of the Wood Construction Workshop of the Department of Civil Engineering FT UNP. The findings of this study are that first; The number of types of static wood work machines used routinely by students / lecturers in wood construction workshops is 6 (six), namely armed-arm circular saws, flattening crabs, thickening crabs, tabled circular saws, chisels, and combination crabs. Second;Forms of work accidents that may occur include the use of machines exceeding normal limits, machine layout, machine maintenance processes, experience of machine use processes, maintenance on machines, the occurrence of short circuit sources on machines, cleanliness of the work environment, and implementation of machine usage procedures. Third; JSA in this study is to control aspects of machine operation including by requiring all students to use complete personal protective equipment, giving obligations to lecturers of courses and practices along with technicians or instructors to strictly supervise the use of machines that have the potential to cause accidents.

Drone: Firefighter

Abstract: This paper introduces the drone: a firefighting device that makes use of low-fee photodiode sensors to discover fires. The layout reduced size, energy consumption and value financial savings even as preserving performance. We speak the machine layout, take a look at strategies, and outcomes, focusing on the effectiveness of infrared radiation detection. The paper concludes with limitation and destiny developments, paving the way for similarity development of drone firefighting generation.

A New Mathematical Model for Cell Layout Problem considering Rotation of Unequal Dimensions of Cells and Machines

One of the main concepts in group technology (GT) is the cellular manufacturing system (CMS) with three main problems of cell formation (CF), cell layout (CL), and cell scheduling (CS). This paper studies the cell layout problem (CLP), aiming to find the optimal layout of machines within each cell (intracellular layout) and the optimal layout of cells in each workshop (intercellular layout). To adapt to reality, the dimensions of the cells and machines (inside each cell) were considered unequal, and also the cells and machines could rotate. We believe that a cellular layout that assumes unequal dimensions of the cells and machines can be used for batch production. This kind of production has a wide variety of low to medium demand. Furthermore, a cellular layout can be applied in CMSs and also in noncontinuous industries that have a job shop layout. Our main contribution is considering the possibility of rotating the cells and machines inside the cells. For this purpose, a mixed nonlinear programming model was developed to solve the CLP with the minimum cost of intracellular and intercellular material flows. The proposed nonlinear model was first converted into a linear model, and then a problem was generated and solved with GAMS software to validate the resulting linear model. This model finds the best layout of cells within the workshop and the best layout of machines inside each cell. Then, because of the NP-hardness of the CLP and the fact that even exact methods cannot solve large-scale examples in an acceptable computational time, an imperialist competitive algorithm (ICA) was designed and used to solve the problem. To evaluate the efficiency of the proposed algorithm, its numerical results in small dimensions were compared with the results of GAMS software. In large dimensions, 30 random problems were created, and the results of ICA were compared with the results of the particle swarm optimization (PSO) algorithm and genetic algorithm (GA). Finally, the parameters of the three meta-heuristic algorithms were set by the Taguchi method. Numerical results indicated that ICA was superior to both the PSO algorithm and GA. It could also achieve efficient solutions in a shorter computational time.

Cell formation and layout design using genetic algorithm and TOPSIS: A case study of Hydraulic Industries State Company.

Cell formation (CF) and machine cell layout are two critical issues in the design of a cellular manufacturing system (CMS). The complexity of the problem has an exponential impact on the time required to compute a solution, making it an NP-hard (complex and non-deterministic polynomial-time hard) problem. Therefore, it has been widely solved using effective meta-heuristics. The paper introduces a novel meta-heuristic strategy that utilizes the Genetic Algorithm (GA) and the Technique of Order Preference Similarity to the Ideal Solution (TOPSIS) to identify the most favorable solution for both flexible CF and machine layout within each cell. GA is employed to identify machine cells and part families based on Grouping Efficiency (GE) as a fitness function. In contrast to previous research, which considered grouping efficiency with a weight factor (q = 0.5), this study utilizes various weight factor values (0.1, 0.3, 0.7, 0.5, and 0.9). The proposed solution suggests using the TOPSIS technique to determine the most suitable value for the weighting factor. This factor is critical in enabling CMS to design the necessary flexibility to control the cell size. The proposed approach aims to arrange machines to enhance GE, System Utilization (SU), and System Flexibility (SF) while minimizing the cost of material handling between machines as well as inter- and intracellular movements (TC). The results of the proposed approach presented here show either better or comparable performance to the benchmark instances collected from existing literature.

Multifunctional Robotic Device with Intelligent Positioning System

At the present stage of agricultural production development, Smart farming is widely used as a systematic transition from managing a separate technological operation to managing processes that ensure the achievement of the required level of overall profitability of production through the use of new decision-making tools and automated management technologies. This approach involves expanding the scope of machines, equipment and software, including the widespread use of robotic tools in horticultural production and processing technologies, in order to increase production efficiency, eliminate the “human factor” in the production of products, replace human participation in production processes with a large proportion of heavy manual labor and minimize harmful effects chemical protection products for humans and the environment. Another reason for the intensification of the development and implementation of robotic tools with intelligent control systems in agriculture is the shortage of technologists and engineers in farms, due to the unattractiveness of labor in the agro-industrial complex. The article discusses the issues of increasing the efficiency of industrial gardening, through the development and implementation of robotic systems and electric drive transformer modules in various technological processes. The features of the designs and practical application of robots with intelligent motion control systems on garden plantations are analyzed. The application of the block-modular principle of the layout of robotic machines is justified to increase the efficiency and productivity of their work in industrial gardening in various technological operations: plant care (spraying, milling of aisles) and harvesting.

Parametric Automated Design and Virtual Simulation of Building Machine Using BIM

With the continuous development of the construction technology of the main structure of high-rise buildings, traditional construction techniques have been widely used in high-rise building projects. However, these technologies have problems such as low safety, low intelligence, and poor integrity. In order to solve these challenges, the Third Engineering Bureau of China Construction independently developed a new type of construction technology—a high-rise building integrated work construction platform (referred to as a building machine). Building machines has been gradually applied to high-rise building projects due to its intelligence, integration, safety, and other advantages. However, with the increase in the number of high-rise building projects, the traditional way of designing building machine layout programs is inefficient and the design program is complicated to change. To solve these problems, this paper proposes a building machine parametric design and layout and virtual simulation method. This method uses Blender open-source software to model the building machine parametrically and quickly using its visual programming tool Geometry Nodes (GN) and simulates the building machine in the virtual scene through the Unity3D platform. The results show that, compared with the traditional design mode, the method proposed in this paper can quickly complete the scheme design in the design phase of the building machine and display it through the 3D model, which has a better visualization effect, improves the design efficiency, and reduces the design cost, and the Unity simulation platform can also provide the construction personnel with pre-shift education and simulation of the operation of the building machine. This method provides a theoretical basis and guidance for the digital construction of the building machine.

HL-LHC layout for fixed-target experiments in ALICE based on crystal-assisted beam halo splitting

The Large Hadron Collider (LHC) at the European Organization for Nuclear Research (CERN) is the world’s largest and most powerful particle accelerator colliding beams of protons and lead ions at energies up to 7 Z TeV, where Z is the atomic number. ALICE is one of the experiments optimised for heavy-ion collisions. A fixed-target experiment in ALICE is being considered to collide a portion of the beam halo, split using a bent crystal inserted in the transverse hierarchy of the LHC collimation system, with an internal target placed a few metres upstream of the existing detector. This study is carried out as a part of the Physics Beyond Collider effort at CERN. Fixed-target collisions offer many physics opportunities related to hadronic matter and the quark-gluon plasma to extend the research potential of the CERN accelerator complex. Production of physics events depends on the particle flux on the target. The machine layout for the fixed-target experiment is developed to provide a flux of particles on the target high enough to exploit the full capabilities of the ALICE detector acquisition system. This paper summarises the fixed-target layout consisting of the crystal assembly, the target and the downstream absorbers. We discuss the conceptual integration of these elements within the LHC ring, the impact on ring losses, and expected performance in terms of particle flux on target.

Minimasi Pemborosan pada Lantai Produksi PT Kunango Jantan dengan Pendekatan Lean Manufacturing

PT Kunango Jantan is one of the private companies engaged in manufacturing and trading. One of the products produced is Street Light Pole (PJU). The production of these PJU poles also faces various challenges. Commonly faced challenges are related to several types of waste on the production floor. This research aims to identify waste on the production floor of PJU poles using a lean manufacturing approach. The results indicate that the top three waste percentages are 18.9% for transportation activities, 17.62% for waiting activities, and 15.46% for defects. Some factors causing these wastages include frequent machine breakdowns, depletion of raw materials due to the lack of raw material scheduling implementation, and frequent transportation during production. Improvement recommendations to reduce waste include scheduling machine maintenance, planning raw material control, and adjusting machine layouts to minimize repetitive transportation.

Design of a separator machine for oil palm fruit mesocarp and nut using computer‐aided design and linear finite element analysis

AbstractThis study addresses the inefficiencies in the current palm oil milling process, where the coexistence of mesocarp fiber and nut during pressing results in oil loss and nut breakage. To tackle this issue, the research aims to develop a machine that can separate mesocarp fibers from nuts before pressing, enhancing oil extraction and quality. The study involves designing the machine layout, creating schematic drawings, wireframe models, and assessing stress and deformation performance. Solidworks simulation was used to determine stress and deformation points within material properties, dimensions, and applied forces. The maximum stress on the rotating disc was 1.44 MPa, with a total deformation of 9.75 x 10−4 mm. Comparing this to the static component strength against cracking (0.093 MPa) revealed that the disc's material and design can safely with stand loads, preventing deformation during the mesocarp and nut separation process. This innovation promises to increase oil yields and improve oil quality in palm oil milling.Practical applicationsThe separation of mesocarp fiber and nuts using centrifugal force is a feasible method. By removing nuts from the mesh (fiber) prior digestion and oil extraction process, the issue of nut breakage will be completely omitted, and thus the pressure can be further increased to maximize oil yield at the palm oil mill industries. This suggested approach has been demonstrated to produce a large amount of oil with minimal broken kernels. The crude palm oil obtained from this separation process also satisfies industrial standards.

A Green Flexible Job-Shop Scheduling Model for Multiple AGVs Considering Carbon Footprint

Green and low carbon automated production has become a research hotspot. In this paper, the AGV transport resource constraint, machine layout and job setup time have been integrated into the background of a flexible job shop. From a whole life-cycle perspective, the AGV allocation strategy has been formulated by simulating multiple scenarios within the production system. Aimed at makespan, carbon footprint, and machine load, a green low-carbon flexible job shop scheduling model with multiple transport equipment (GFJSP-MT) has been constructed. To address this problem, a relevant case dataset was formed, and a heuristic strategy NSGA-II using a real number encoded embedded cycle to replace repeated individuals was proposed. Through longitudinal and horizontal comparisons, the effectiveness of the AGV allocation strategy has been verified and the optimum number of AGVs in the case determined. Finally the quality and diversity of the Pareto frontier solutions are compared and the scheduling scheme for each sub-objective are discussed. The results show that the model and algorithm constructed in this paper can effectively achieve the optimal scheduling of green flexible shop production.

Studi Kelayakan Bisnis Umkm Kota Tangerang (Studi Kasus Usaha Soto Daging Sapi “Mbah Man” Kondang Rasa)

UMKM Soto Beef "Mbah Man" Kondang Rasa is one of the MSMEs in Tangerang City engaged in culinary. In business development, it is necessary to analyze the feasibility of investment with a financial aspect approach and technical feasibility with a technical aspect approach which will ultimately produce an assessment or decision whether this business should be developed or not. Data collection method with direct observation and interview and data processing by tabulating data that refers to the calculation of aspects of investment feasibility analysis, namely Net Present Value (NPV), Payback Period (PP), Internal Rate of Return (IRR), and Profitability Index (PI) as well as technical aspect approach analysis. The results of the technical aspect approach are declared feasible in determining the location, layout and readiness of machines, the best inventory methods, and the need for labor. Meanwhile, the feasibility from the financial aspect shows that the business is feasible to run with eligibility criteria that produce a Payback Period (PP) for 2 months 27 days, a Net Present Value (NPV) value of IDR 1,285,373,578, an Internal Rate of Return (IRR) value of 7.68% > 7% (interest rates), and a Profitability Index (PI) value of 14.60 >1 Keywords: MSMEs, Business Feasibility, Financial Aspects, Technical Aspects

Good Manufacturing Practices (GMP) Implementation Training for Improving the Quality and Safety of UKM Santan XX in Batam City

Toko Santan XX located in Nongsa District, Batam City processes coconut into coconut milk that is ready to consume by consumers. Processing is still conducted manually and a makeshift coconut grinding machine. It is not enough to support the high demand for coconut milk because Toko Santan XX has many customers in the region. In assessing the quality and safety of food management processes, Good Manufacturing Practices (GMP) studies can be used. Therefore, based on the situation analysis that has been carried out, this community service intends to provide Good Manufacturing Practices (GMP) training to Toko Santan XX. Good Manufacturing Practices (GMP) contain minimum requirements and general processing that must be met in food processing, from raw materials to final products. The purpose of the assessment is to make Toko Santan XX can create higher quality products and more efficient management. The GMP assessment was carried out using 14 assessment aspects, the average percentage was 59.45. This means that it is enough for Toko Santan XX to implement GMP at its place of business, but it still needs to be improved. Recommendations for improvements that need to be made include making SOPs based on the order of coconut milk production so that work is more organized, improving the layout of coconut milk processing tools and machines to increase productivity, and avoiding unnecessary movements. In addition, there needs to be an awareness of HSE at Toko Santan XX.

Designing robust capability-based distributed machine layouts with random machine availability and fuzzy demand/process flow information

Designing robust capability-based distributed machine layouts with random machine availability and fuzzy demand/process flow information

Projecting robot dynamics onto trajectories

AbstractMachines and mechanisms realize processes, from the shaping process of a milling machine and the motion process of an automotive system to the trajectory realization of a robot. The dynamics of a machine generated by a properly chosen set of constraints in combination with an appropriate drive system is designed to meet the prescribed requirements of the process, which is done by projecting the machine equations of motion on the process dynamics. We get a set of nonlinear relations, which represent the machine motion in terms of the required process motion. A well-known example is the projection of arbitrary many robot degrees of freedom (DOFs) on a given path resulting in a set of nonlinear equations with one DOF only, the path coordinate s. Application of this idea can be used to construct a mobility space $(\ddot{s}, \dot{s}, s)$ for any combination of coordinates and constraints. The paper presents a corresponding approach for n-link robots by applying multibody system theory. Method might be interesting for layout of machines and mechanisms. Practical aspects are discussed, and an example is given.

An Optimal Layout Pattern-Based Solution Approach to the Extended Machine Layout Problem With Multirow Multicolumn Structure

The machine layout problem (MLP) is to determine the optimal location arrangement of machines in a production system, usually in order to minimize the total material transmission distance. This article considers a type of MLP in an automated manufacturing system with unequal-area machines, machine replicas, and taking multi-row multi-column layout structure. The aim is to determine the near-optimal machine layout and orbit layout simultaneously. We model the problem as a mixed-integer linear program by introducing the concept of orbit-based relative locations and using auxiliary binary variables, including relative location assignment variables, in-block relationship variables, and material routing variables. We further exploit the optimal layout patterns, based on which, when the relative locations of the machines and orbits are given, we can quickly derive the near-optimal absolute machine and orbit positions without solving a mixed-integer linear program. A two-layer hybrid heuristic method is proposed to solve the problem: the outer layer is a variable neighborhood search metaheuristic used to explore the solution space of the relative locations, while the inner layer is a recursive heuristic based on the optimal layout patterns. Experiments on instances of different sizes are conducted, and the effectiveness and efficiency of the proposed algorithms are verified. Note to Practitioners—Many manufacturing systems, for example, those in the semiconductor industry, use automated guided vehicles running on orbits to transfer materials between machines. The design of such a manufacturing system consists of determining the numbers of vertical and horizontal orbits, their positions, and the positions of all machines. It is not unusual for there to be hundreds of machines. Furthermore, machines of the same type can be deployed non-adjacently in an automated transfer context since materials can easily be transmitted to an arbitrary machine. The flexibility and complexity of the layout make this layout problem extremely difficult to solve. To the best of our knowledge, no dedicated study has been conducted on this issue. Additionally, state-of-the-art methodologies for related machine layout problems cannot be extended to this problem, partly because one needs to consider the material routing problem explicitly on the orbit network. In this study, we reveal the optimal layout patterns given the relative locations of machines and orbits, and we develop a recursive heuristic that is thousands of times faster than solving the corresponding mixed-integer linear program. Our proposed two-layer hybrid heuristics can solve problems with hundreds of machines, while the inner-layer problem’s precision is guaranteed to within 1%. We believe our algorithm can be used for machine and orbit layout design in flexible manufacturing systems where machine-to-machine material shipment is enables in a rectangular trasmission network.

Integrating machine layout, transporter allocation and worker assignment into job-shop scheduling solved by an improved non-dominated sorting genetic algorithm

To meet the everchanging production demand and close to the actual scheduling environment, a multi-objective job-shop scheduling problem (MOJSP) with multiple resource constraints is investigated. Specifically, an integrated mathematical model is constructed based on a job-shop scheduling problem (JSP) considering machine layout rearrangement, transporter allocation with capacity limitation, and worker assignment with skill variance to simultaneously minimize the exit time, labor cost, worker workload difference, and transportation time. To tackle the concerned problem, an improved non-dominated sorting genetic algorithm with a hybrid local search (INSGA-HLS) is designed. In the numerical simulation, a test dataset is first constructed according to the literature. Second, an orthogonal experiment is utilized to find the best combination of key parameters for INSGA-HLS. Third, the exploitation competence of the proposed hybrid local search (HLS) is verified. Then, the superiority of the designed INSGA-HLS algorithm is demonstrated by comparing it with the other intelligent algorithms. Thereafter, the influence of three considered factors on the integrated scheduling problem is illustrated: (1) flexible machine layout rearrangement may reduce the handling time, and improve production efficiency to some extent; (2) transporter capacity limitation can prolong the transport time, which extends the exit time; and (3) worker assignment with skill variance can not only improve productivity and reduce the labor cost, but also narrow the workload difference to improve employee satisfaction. Finally, an actual production line application further verifies the practicability and benefit of the model, and the managerial significance is analyzed.

ANALISA KEBIJAKAN MITIGASI DAMPAK DAN STRATEGI PENURUNAN GAS RUMAH KACA DI PT XYZ MENGGUNAKAN METODE ANALYTIC HIERARCHY PROCESS (AHP)

Environmental issues have now become a critical topic for the attention of countries around the world, especially efforts to prevent climate change by mitigating greenhouse impacts. There are six types of greenhouse gases, namely Carbon dioxide (CO2), Methane ( CH4 ), Nitrous oxide ( N2O ), Hydro perfluorocarbons ( HFC ), Perfluorocarbons ( CFCs ), Sulfur Hexafluoride ( SF6) this which naturally exists in the air (atmosphere). The gas layer causes infrared heat rays A to reflect sunlight, causing geothermal heat that reaches 13°C. The earth's temperature will increase when the greenhouse gas layer gets bigger. Increased greenhouse gas (GHG) concentrations contribute to climate change by destroying stratospheric ozone and trapping excessive heat in the atmosphere. CO2 contributes 76.7% of total GHG emissions. Industrial activities are suspected to be one of the sources of co2 emission production. Research using the Analytic Hierarchy Process (AHP) method aims to analyze impact mitigation policies and GHG reduction strategies carried out by PT XYZ as one of the manufacturing industries committed to contributing to mitigating the impact of greenhouse gases. The research results obtained the Priority Policy on the operation of production machines at the Factory 1 location. The strategies carried out include replacing old machines that are no longer efficient with new machines that are more productive, and efficient in their electricity use, the use of high technology, and changing the layout or layout of machines that are more compact and grouped based on the type of product. From the analysis using the Analytical Hierarchy Process (AHP) method, it was concluded that the most priority greenhouse gas (GHG) impact mitigation policy was to reduce CO2 emissions based on the use of electrical energy by Reducing the use of electrical energy.