Material Handling Cost Research Articles

Grouping technology and a hybrid genetic algorithm‐desirability function approach for optimum design of cellular manufacturing systems

Cell formation and machine layout in cellular manufacturing systems (CMs) design are considered as a crucial, yet hard and complex decision process. Owing to the nondeterministic polynomial time (NP) and combinatorial class of this problem, this paper presents an innovative heuristic approach to re-arrange machines enabling the minimisation of inter/intra- cellular movements as well as the cost of material handling between machines, therefore increasing group efficiency and efficacy. The heuristic approach, which is based on group technology, genetic algorithms, and desirability function, determines the optimal solution for flexible cell formation and machine layout within each cell. Flexibility refers to an explicit improvement using the desirability function to modify cell design by altering the ratio data; that is, the weight factor to meet demand flexibility. Specifically, the desirable function proposed here to provide the optimal setting of the weighting factor as a key factor which enables CMs design the flexibility to control the cell size. Promised results were obtained when the proposed approach was applied to a case study. Practical implications and recommendations are provided for use by decision makers in the design of CMs.

Design of Sand Blasting Machine

Abstract: When a metal is exposed to atmosphere, it gets corroded by atmospheric air. To overcome this sand blasting process are used. When machining leaves the sharp burrs or edges on an object, sandblasters can smooth it until it is safe to handle. Sand blasting is a method used to clean, polish or strengthen metal with the help of abrasive material. Sand blasting is used in almost every industry that uses metal, including aerospace, automotive, construction, shipbuilding, rail, and many others. Sand blasting machines uses abrasive material like steel grit, glass bead, sand. The blast media is pneumatically accelerated by compressed air and projected by nozzles onto the component to roughen a smooth surface, shape a surface or remove surface contaminants. For the application of sand blasting process on a big component, which may require secondary surface treatment, which is carried out in a confined space, so many times we have to shift jobs to confined room. Due to this material handling cost increases. To avoid this, there is need of design of portable type of sand blasting machine. Keywords: Sand Blasting, Abrasive Material, Surface Treatment Process, Material Handling Cost, Portable

Redesain Tata Letak Pabrik Gula dalam Meningkatkan Efesiensi dan Produktivitas CV. Rizki Abadi

This study aims to improve the layout of CV Rizki Abadi's production facilities so as to increase efficiency and productivity. Redesign of the company needs to be done because consumer demand is often not met until it reaches 64.5 tons in 2020. This study only discusses material handling costs, productivity percentages, and the layout improvement model chosen by the factory owner from the three models proposed by the researcher. The layout analysis in this study uses the CRAFT algorithm. The CRAFT algorithm can provide the best layout improvement model output after exchanging the location of the facilities. The analysis shows that the total cost of material handling in the initial layout is Rp. 2,950,838. After repairs were made using the CRAFT algorithm and approved by the factory owner (model 3) by exchanging facilities between Work Station 3 (Draining) and Work Station 2 (Mold Stacking), material handling costs were more efficient to only Rp. 1,257,115.5 or 2 ,25%. Initial layout productivity also increased from 14.27% to 16.6%.

Minimization of Total Variable Cost through Determination of Batch Transfer Size at m Serial CNC-Machining Centers

Background: In a batch production series consisting of several process stages for discrete products, the determination of the transfer batch size greatly affects the batch waiting time. For production using a Computer Numerical Control (CNC)-machining center, several process stages can be carried out on one machine with quick setup. The use of a single machine for all stages of the process certainly does not require transfer to the next machine. Thus, there are no material handling costs. However, the use of a single machine will result in longer batch waiting times as the production batch size increases. An increase in the batch waiting time will result in an increase in work-in-process (WIP) inventory cost. This research was conducted to reduce the total variable cost consisting of WIP inventory cost and material handling cost. Methods: This research was conducted in two steps. The first step is to divide the process stages, I into m serial CNC machining centers, where in this study I=m. The second step is to determine the same size of transfer batch, Qij for a certain number of transfers, J that produces the minimum total variable cost. Results: The results showed that J=5 resulted in a total variable cost of Rp. 146,800.00, while J=10 resulted in a total variable cost of Rp. 178,900.00. Conclusion: In conclusion, the total variable cost decreases if the size of transfer batch is reduced to a certain amount and will increase again along with the reduction in the size of transfer batch.

A two-stage solution approach for unequal area facility layout problem with bi-directional relaxed flexible bay structure

PurposeThe purpose of this article is to develop a bi-directional relaxed flexible bay structure (BRFBS) in the layout for the unequal area facility layout problems (UA-FLPs) and test the suitability of the proposed approach using literature data.Design/methodology/approachThis research adopts a two-stage solution approach for UA-FLPs to form BRFBS in the layout. The solution to UA-FLPs is carried out in discrete space. The proposed heuristic method optimises the layout plan for minimising the material handling cost (MHC), and also, it indirectly optimises the space utilisation by reducing the empty space in the layout. The first stage of layout design assumes that all facilities are equal in size and uses quadratic assignment problem (QAP) model. QAP is solved with a simulated annealing heuristic method. In the second stage, a heuristic method is proposed to find the optimum width for each bay and the dimension for facilities. The proposed heuristic method is tested with numerical data available in the literature. Results are compared with the results obtained by layout planning software, and with the simulated annealing algorithm for flexible bay structure (SA-FBS) heuristic procedure for continuous space UA-FLPs.FindingsThe proposed two-stage solution approach gives the BRFBS for the UA-FLPs. BRFBS helps to create proper aisle structure in the layout plan. The layout configuration and solution of the proposed method is better than the layout planning software solution and SA-FBS solution. The application of the proposed heuristic method to case data gave lesser MHC, better space utilisation and better aisle formation than the existing layout.Research limitations/implicationsThe proposed approach has the limitation that it can be applied only to UA-FLPs solved in discrete space. When the UA-FLPs are solved in continuous space, then it is not possible to make application of this approach to form bi-directional relaxed flexible bays in the layout plan.Practical implicationsMost of the modern industries are automated, and they use material handling equipment (MHE) like automated guided vehicles (AGVs). Design of layout plans that help to create proper aisle structure for AGV’s in the layout plan is a challenging to the researchers. The BRFBS configuration is more suitable in the flexible manufacturing system where AGVs are used for material transportation.Originality/valueThis paper proposes a novel two-stage heuristic method for solving the UA-FLPs in discrete space. The proposed approach generates a BRFBS in the layout plan. The BRFBS helps to create a proper aisle structure suitable for better material handling operations. Hence, this type of layout helps in easy interaction of the MHE (e.g. AGVs) with the boundaries of the facilities touching the aisle.

Unequal area facility layout problem-solving: a real case study on an air-conditioner production shop floor

Solving facility layout problems aims at identifying the optimal plan for placing a number of facilities or departments on a shop floor considering multiple optimisation criteria and constraints. Recently, the unequal area facility layout problem (UA-FLP) has drawn more attention as it is closer to real industrial scenarios. To address this problem, the typical UA-FLP in an air-conditioner production shop floor is analysed, and then a modified non-dominated sorting genetic algorithm (NSGA-II) is developed to identify the optimal layout plan considering the material handling cost (MHC) and the closeness rating score (CRS). NSGA-II is a stable algorithm for engineering applications and has an encoding structure of chromosomes that can express facility layout expediently. Besides that, the two objectives (MHC and CRS) that are conflicting might be another reason for adopting NSGA-II. During the process, the crossover and mutation operators of NSGA-II are modified based on the non-overlapping method, which reduces the time cost for eliminating unsuitable layout plans. The modified NSGA-II is compared with two related algorithms, and the results show that it has better performance on the UA-FLP with a large number of departments.

Peningkatan Efisiensi Penanganan Material Melalui Perancangan Tata Letak Fasilitas dengan Integrasi Metode Konvensional Tata Letak dan Algoritma CORELAP

Material handling methods determine the effectiveness and efficiency of a company. This research was conducted at PT. FIM which is a manufacturing company that produces food packaging made of plastic (plastic food grade packaging), which has ineffective and inefficient material handling problems. The main objective of this research is to design the facilities layout of PT.FIM to improve the efficiency of material handling. In this research, the integration of the conventional layout method and the CORELAP algorithm was used to determine the optimal work station layout. The research stage begins with calculation of the routing sheet based on the OPC, calculation of the floor area and making of ARC in the production area using the CORELAP algorithm method, while for other facility areas using the conventional layout method. The next stage is making ARD and AAD, and conducting MHPS analysis. From the results of this research obtained a layout design that requires the addition of 6 injection machines, a production floor area of 922m2, a raw material warehouse of 26.65m2, a finished materials warehouse of 63.96m2, a work-in-process warehouse of 85.28m2, supporting materials warehouse of 14.34m2, office area and other facilities area of 462m2. The resulting layout design has a material handling distance difference of 49.3m, and a cost difference of Rp.51,978, with a material handling cost efficiency of 78.67%.

Logistic models to minimize the material handling cost within a cross-dock.

Retail supply chains are intended to empower effectiveness, speed, and cost-savings, guaranteeing that items get to the end client brilliantly, giving rise to the new logistic strategy of cross-docking. Cross-docking popularity depends heavily on properly executing operational-level policies like assigning doors to trucks or handling resources to doors. This paper proposes a linear programming model based on door-to-storage assignment. The model aims to optimize the material handling cost within a cross-dock when goods are unloaded and transferred from the dock area to the storage area. A fraction of the products unloaded at the incoming gates is assigned to different storage zones depending on their demand frequency and the loading sequence. Numerical example considering a varying number of inbound cars, doors, products, and storage areas is analyzed, and the result proves that the cost can be minimized or savings can be intensified based on the feasibility of the research problem. The result explains that a variation in the number of inbound trucks, product quantity, and per-pallet handling prices influences the net material handling cost. However, it remains unaffected by the alteration in the number of material handling resources. The result also verifies that applying direct transfer of product through cross-docking is economical as fewer products in storage reduce the handling cost.

Optimization of Multi-Objective Unequal Area Facility Layout

The unequal area facility layout problem (UA-FLP) refers to the reasonable arrangement of a certain number of facilities in a given layout area. The facility layout should satisfy given layout constraints and optimize given optimization objectives as far as possible. In this paper, a method combining improved lowest horizontal line method and particle swarm optimization algorithm is proposed to solve UA-FLP, which achieves multi-objective optimization of material handling cost, the adjacent value and the utilization rate of floor shop. On the one hand, the algorithm formulates facility packing rules through the improved lowest horizontal line method, which simplifies the legalization of facility layout. On the other hand, a modified particle swarm optimization (PSO) algorithm combining objective space division method (OSD) and niche technology is used for multi-objective optimization. The proposed algorithm overcomes the shortcomings of previous facility layout methods such as complex overlapping interference process, large amount of calculation and long time for multi-objective optimization. Compared with the comparison methods, the results show that material handling cost is reduced by 1%–6% and the utilization ratio of floor shop is increased by 2%–7%.

Perancangan Ulang Tata Letak Fasilitas Produksi dengan Metode Systematic Layout Planning dan BLOCPLAN untuk Meminimasi Biaya Material Handling pada UD. Sofi Garmen

The competitions among industries will get increasing and grow rapidly along with the advan/cement of technology. The layout of company facilities must be considered well as it holds a vital role in determining the quality of production process. Sofi Garmen Firm has encountered a problem of far distance in material handling among departments that finally triggered disturbance of production activity and huge cost of material handling. Therefore, a design for relayouting production facilities became the research object. It aimed at designing the layout proposal through Systematic Layout Planning and Blocplan methods. To calculate the distance, the researcher employed Rectilinear and Euclidean. The result of both distance calculations in Systematic Layout Planning obtained 29,678.5 meters and 23,375 meters respectively, whereas the cost of material handling gained averagely IDR 1,129,356.5. Meanwhile, the results of distance calculations of Rectilinear and Euclidean in Blocplan earned 30,920 meters and 26,942.5 meters consecutively and the cost of material handling produced averagely IDR 1,237,564.5. Accordingly, the calculation results indicated that the recommendation yielded by Systematic Layout Planning became the most optimum alternative of layout.

PERANCANGAN ULANG TATA LETAK FASILITAS PRODUKSI DENGAN METODE GRAFIK DAN METODE CRAFT DI UD. PRIMADONA

UD. Primadona is a company that sells typical Jember snacks. At the moment, the condition of the facility layout of UD. Primadona faced many problems. One of them is a distinctive design that there is a long flow of material transfer. Transferring materials from the cutting department to the packaging department must go through the production department passed (backtrack). This flow can lead to a big total displacement moment, allowing an increase in material handling costs and indirectly increasing production costs. So, it is necessary to make or change the layout to be more effective and efficient. This study aimed to design using two methods, the CRAFT method and the Graph method. The results showed that alternative graphic method 2 was the best solution based on Material Handling Cost (OMH). This method has less displacement moment per day, and total OMH than the existing design, 89 meters per day and Rp. 7,039.90 respectively.

PERANCANGAN ULANG TATA LETAK FASILITAS PRODUKSI MENGGUNAKAN METODE ALGORITMA CRAFT PADA PT. SERMANI STEEL MAKASSAR

Factory layout is one of the most important problems in a company, because the arrangement of facilities affects the efficiency and cost of manufacturing products. PT. Sermani Steel of Makassar City is one of the companies engaged in the manufacture or production of zinc-coated steel sheets (Zn) with a production capacity of 3000 tons/year, the problem that occurs is that the layout of related departments is far apart, causing large moving costs. The CRAFT Algorithm method is an improvement program that seeks optimum planning by making improvements in stages with the help of the WinQsb software. The CRAFT algorithm method can describe each department and calculate the Material Handling Cost (OMH) experienced by the product during the production process. Based on the results of research conducted, the cost of moving materials in the initial layout is Rp. 1,636,270,800/year after repairing the layout of the facility, the transfer fee is Rp. 1,467,309,300/year with a difference of Rp. 168,961,500 per year, material transfer costs have decreased by 10% from the initial layout.

STRATEGI PENENTUAN LAYOUT GUDANG PT. MEGAH BANGUNAN ABADI GUNA MEMINIMALKAN JARAK DALAM PROSES BONGKAR MUAT


 Determination of warehouse layout is important for companies engaged in the field of distributors. The purpose of this research is to find out how the process in designing the proposed layout of product warehouses in PT. Megah Bangunan Abadi and to know the efficient level of layout of new proposals against distance and cost in the loading and unloading process at the product warehouse. This research uses quantitative descriptive research methods. If all data is collected then then calculate the distance between departments, determine the cost of material handling and create from to chart and then process the data using software WinQSB to obtain the final iteration to compare with the initial layout. The results of this study show that there are 3 proposed layouts. From the proposed warehouse layout obtained the amount of distance 2.067,35 m with the total distance of the initial layout 2.373 m and has a level of 12,88 % efficiency compared to the initial layout. In total cost layout the final proposal has a total cost of Rp.18.922.030 with the total initial cost of Rp 39.926.050 and the new proposed warehouse layout has an efficiency level of 52,6% compared to the initial layout.

Soft Computing Methodology to Optimize the Integrated Dynamic Models of Cellular Manufacturing Systems in a Robust Environment

Machine learning, neural networks, and metaheuristic algorithms are relatively new subjects, closely related to each other: learning is somehow an intrinsic part of all of them. On the other hand, cell formation (CF) and facility layout design are the two fundamental steps in the CMS implementation. To get a successful CMS design, addressing the interrelated decisions simultaneously is important. In this article, a new nonlinear mixed-integer programming model is presented which comprehensively considers solving the integrated dynamic cell formation and inter/intracell layouts in continuous space. In the proposed model, cells are configured in flexible shapes during the planning horizon considering cell capacity in each period. This study considers the exact information about facility layout design and material handling cost. The proposed model is an NP-hard mixed-integer nonlinear programming model. To optimize the proposed problem, first, three metaheuristic algorithms, that is, Genetic Algorithm (GA), Keshtel Algorithm (KA), and Red Deer Algorithm (RDA), are employed. Then, to further improve the quality of the solutions, using machine learning approaches and combining the results of the aforementioned algorithms, a new metaheuristic algorithm is proposed. Numerical examples, sensitivity analyses, and comparisons of the performances of the algorithms are conducted.

Physical characterization and mass modeling of traditionally Popped Makhana (Euryale ferox Salisbury) variety: Sabour‐1 Makhana

AbstractCorrelation between physical properties of Popped Makhana (variety: Sabour‐1 Makhana) such as tri‐axial dimensions, spatial diameters, projected areas, volumes and mass may aid in predicting pops quality besides fabrication of post‐harvest machinery. Hence, the present work aims to predict the mass of Makhana pops as a function of its physical attributes using nonlinear mathematical models. Depending upon high variation in mass data (0.19–0.46 g), pops were categorized into small, medium and large groups presented with suitable mass models. The medium mass group (MMG) was found dominating since 70% of the overall selected samples belonged to this group approaching ellipsoid. Quadratic model was recommended to predict mass for MMG based on tri‐axial dimension thickness (T), R2 = 0.806; spatial diameter (Dg), R2 = 0.898; projected area (PT2), R2 = 0.873; and ellipsoidal volume (Vellip), R2 = 0.895, respectively. Further investigation comprised of various physical, aerodynamic, gravimetric, frictional, color, and mechanical properties. The mean surface area, true volume, and bulk porosity of pops were 881.37 mm2, 2,446.96 mm3, and 25.49%, respectively. The sphericity, aspect ratio, elongation, and flakiness ratio were determined as 0.85, 0.90, 1.12, and 0.79, respectively. Terminal velocity for pops and its associated drag force were obtained as 6.82 ms−1 and 3.12 × 10−5 N, respectively. Galvanized aluminium sheet offered both lower angle of inclination and coefficient of static friction (11.53°, 0.20). L* (64.39) and whiteness index (59.95) values indicated “opaque white” tone. For lower measure of cohesiveness (0.38) and resilience (0.14), higher gumminess (21.80) was obtained along with bowl‐life texture.Practical ApplicationsPopped Makhana is a light, voluminous, traditionally expanded pseudocereal consumed as breakfast cereal or roasted snack. It involves labor intensive manual grading, bag filling, weighing, packaging in various sizes, etc., resisting its consumer acceptability, export promotion and domestic consumption as well. Appropriate grading could be efficiently achieved by mass modeling tool, establishing the relation between physical quantities and mass. Mass based grading is economically superior than size grading, slashing grading time, packaging and material handling costs. Mass based mathematical modeling optimizes packaging formations and reduces volume for low transportation cost to distance places for product development. The assessment of projected area for mass prognosis outlines usage of single camera as the vital part of grading system, ensuring economic feasibility. Thus, research was inducted to investigate mass modeling of Popped Makhana based on the selected engineering attributes to develop an automatic grading system based on combined approach of mass and size.

Optimasi Biaya Distribusi Multi-eselon untuk Multi-produk Menggunakan Mix Integer Linier Programming

The transportation problem is one of the fundamental problems in distribution network to minimize transportation costs by considering resource constraints and meeting the customer demand. This study aims to minimize distribution costs of a distribution networks of soft drink company using the Mix Integer Linear Programming (MILP). This optimization method considers transportation costs, material handling and transportation costs. The addition of a distribution center (DC) as a consolidation center of goods sent to retailers makes the distribution process more efficient. Facility and material handling costs in DC, can be compensated with lower transportation costs. The suggested network can reduce distribution costs by 15.29% compared to the existing methods.

Optimasi Biaya Distribusi Multi-eselon untuk Multi-produk Menggunakan Mix Integer Linier Programming

The transportation problem is one of the fundamental problems in distribution network to minimize transportation costs by considering resource constraints and meeting the customer demand. This study aims to minimize distribution costs of a distribution networks of soft drink company using the Mix Integer Linear Programming (MILP). This optimization method considers transportation costs, material handling and transportation costs. The addition of a distribution center (DC) as a consolidation center of goods sent to retailers makes the distribution process more efficient. Facility and material handling costs in DC, can be compensated with lower transportation costs. The suggested network can reduce distribution costs by 15.29% compared to the existing methods.

Applying reinforcement learning to plan manufacturing material handling

Applying machine learning methods to improve the efficiency of complex manufacturing processes, such as material handling, can be challenging. The interconnectedness of the multiple components that make up real-world manufacturing processes and the typically very large number of variables required to specify procedures and plans within them combine to make it very difficult to map the details of such processes to a formal mathematical representation suitable for conventional optimization methods. Instead, in this work reinforcement learning was applied to produce increasingly efficient plans for material handling in representative manufacturing facilities. Doing so included defining a formal representation of a realistically complex material handling plan, specifying a set of suitable plan change operators as reinforcement learning actions, implementing a simulation-based multi-objective reward function that considers multiple components of material handling costs, and abstracting the many possible material handling plans into a state set small enough to enable reinforcement learning. Experimentation with multiple material handling plans on two separate factory layouts indicated that reinforcement learning could consistently reduce the cost of material handling. This work demonstrates the applicability of reinforcement learning with a multi-objective reward function to realistically complex material handling processes.

Analysis of Bread Production Facilities Layout using BLOCPLAN Algorithm

This study aims to obtain an optimal facility layout by considering the distance between the workstations, transfer time, and material handling cost in a bakery. The research was conducted at a medium-scale bread producer CV Mumtaz Bakery in Banjarbaru City, South Kalimantan. The initial layout of CV Mumtaz Bakery's production facilities is considered as not optimal for production capacity up to 500 kg per day. The layout analysis and the appearance of improvement alternatives were carried out using the BLOCPLAN algorithm, and then the design implementation was carried out using CorelDraw software. Determination of the best layout alternative is based on the highest R-Score. The results showed that the best layout was the one with an R-Score of 0.86. This selected workstation layout has a total distance between processing stations of 31.70 m, a total transfer time of 25 seconds, and a material handling cost of IDR 434.29 for each batch. This layout will reduce the total material transfer distance and the material transfer time from the initial layout by 14.67% and 10.7% respectively.

Sosialisasi Usulan Perancangan Tata Letak Pabrik Pada PT Sari Kayu, Jakarta Timur

The problem faced by PT Sari Kayu is that fluctuating production demand and high product variance make production inefficient. If the problem does not have a good factory layout, it affects material handling costs, material handling distances, and material handling time. For example, at PT Sari Kayu, there was a delay during a wrong project because the two projects were running simultaneously. The delay is due to the lack of resistance of the production floor to sudden high fluctuations in production demand. In addition, product variance is also a factor in the longer production process due to the different sequence of production processes and less supportive machine layouts. It is hoped that with the proposed layout, PT Sari Kayu will be able to face the fluctuating demand for production.