Total Cost Of Material Handling Research Articles

Sequential use of blocplan, solver, and particle swarm optimization (PSO) to optimize the double row facility layout

Facility layout optimization is used to increase company productivity by minimizing waste on transportation, movement, and waiting time. It was mentioned in several previous studies that optimal facility layout can reduce production costs by up to 40%. Because of this importance, many previous researchers have carried out research in the field of Facility Layout. The differences between each Facility Layout research are in the characteristics and criteria being analyzed and the optimization method used. The several approaches used to optimize the layout are constructed algorithm, exact algorithm, and metaheuristic. These three methods have their respective purposes and to the best of our knowledge have not been used sequentially. So, this study aims to find the best layout for the double-row facility problem with aisle width consideration using three sequential methods. There are BLOCPLAN for the constructed algorithm, solver for the exact algorithm, and Particle Swarm Optimization (PSO) for the metaheuristic. The result shows that the use of BLOCPLAN gives a better result of Total Material Handling Cost (TMHC) in PSO. For more machines, PSO has better results than Gurobi Optimization.

Hybridization in meta-heuristic techniques for green layout design in the tyre manufacturing industry: An optimal analysis

To stop or lessen factory pollution, many academics in the field of study have produced a vast array of strategies to achieve optimization goals. But, it is unable to follow a uniform solution for all production facilities. In this research work, green layout design (GLD) is proposed to minimize total material handling cost (TMHC) and CO2 emissions. The green facility layout refers to the facility layout with minimum CO2 emissions and to eliminate unnecessary energy dissipation from material handling equipments & production machineries, as well as plant re-layout in-term on material handling cost. In this study context, a Lagrangian relaxation model has been used at the allocation level. It computes a suboptimal solution to the dual problem in order to obtain a feasible solution. This enhanced algorithm method iteratively tries to minimize the gap between the dual and feasible solutions on minimal of TMHC and CO2 emission rate. It has been experimentally simulated using the MATLAB (Matrix Laboratory) application and upgraded adaptive salp swarm optimization (ASSO), dragon fly optimization (DFO) and Hybrid (combination) of ASSO-DFO evolutionary optimization techniques. The primary focus of this implementation is to control material handling between departments or cells, production flow between departments, energy consumption (electrical and gas consumption for production), and manpower utilization within and across departments. This research has chosen an existing and acceptable designs from targeted tyre manufacturing company in South India. The hybrid ASSO-DFO implementation TMHC differs from ABC by 60%, DFO by 65%, 58% with simulated annealing (SA), and ASSO by 48%. Emission rate decreased by 26% ABC, 21% DFO, and 24% SA & 18% with ASSO. An average of 50% decrease in TMHC and 25% reduction of CO2 emission rate in GLD have been achieved.

A Mixed-Integer Programming Formulation for a Simplified Model of the Double Row Layout Problem

The double row layout problem (DRLP) is to assign facilities on two rows in parallel so that the total cost of material handling among facilities is minimized. Since it is vital to save cost and enhance productivity, the DRLP plays an important role in many application fields. Nevertheless, it is very hard to handle the DRLP because of its complex model. In this paper, we consider a new simplified model for the DRLP (SM-DRLP) and provide a mixed integer programming (MIP) formulation for it. The continuous decision variables of the DRLP are divided into two parts: start points of double rows and adjustable clearances between adjacent facilities. The former one is considered in the new simplified model for the DRLP with the purpose of maintaining solution quality, while the latter one is not taken into account with the purpose of reducing computational time. To evaluate its performance, our SM-DRLP is compared with the model of a general DRLP and the model of another simplified DRLP. The experimental results show the efficiency of our proposed model.

Desain Tata Letak Gudang untuk Meminimalkan Ongkos Material Handling pada PT. Rotaryana Prima

The layout of facilities that are less regular can result in an increase in costs. Placement of goods that are not appropriate and do not pay attention to the distance of movement of goods, this can cause several problems, especially in the movement of material handling. From the emergence of some of these problems, this study aims to determine the layout design of warehouse facilities and minimize material movement distances and reduce costs in material handling. The method to be used is quantitative analysis by calculating distance, frequency, material handling moments and material handling costs to determine the outcome of the redesign process. The results obtained from this study are the total cost of material handling in the initial layout of IDR 3,681,600/month with 60 m from the loading and unloading place to the warehouse and the total cost of material handling in the proposed layout is IDR 2,761,200/month with distance of 45 m from the place of loading and unloading to the warehouse

A bottom-up multi-objective optimisation approach to dynamic facility layout planning

Dynamic facility layout planning (DFLP) involves determining an appropriate arrangement scheme of the elements making up the production system for each time period into which the planning horizon is divided. When formulating the problem as an optimisation model, using the traditional top-down approach is usual, which firstly determines the block layout (BL) and then the detailed layout (DL) of each work cell. However by this approach, the BL generates area constraints in the detailed phase, which sometimes limit its implementation. In this context, the present paper presents a multi-objective mixed integer non-linear programming (MOMINLP) model that allows the problem to be addressed by considering an alternative approach, known in the literature as the bottom-up approach. The proposed model, called bottom-up mDFLP, considers three objective functions: (1) minimise the total material handling cost (TMHC) and the total rearrangement cost (TRAC); (2) maximise the total closeness rating (TCR) between departments; (3) maximise the area utilisation ratio (AUR). The original MOMINLP is transformed into a more computationally efficient multi-objective mixed integer linear programming (MOMILP) model. The proposed model is applied and validated in a case study of a company in the metal-mechanic sector with 12 departments for three 4-month periods.

A fast two-stage hybrid meta-heuristic algorithm for robust corridor allocation problem

The optimisation of the corridor allocation problem (CAP) belongs to the optimisation of the efficiency of the automated production line. The goal is to reduce the material handling cost (MHC) in the production process through a reasonable layout of the facilities, so as to save expenses for the enterprise. In recent years, with the acceleration of market changes, product design and production process adjustments have become more frequent, and more attention has been paid to the research on the layout of facilities under the condition of changes in the flow of materials between production facilities over time. On the basis of the CAP model, this paper considers the optimisation problem of row layout when the flow of materials between facilities fluctuates in a certain range. The new model can be utilised to obtain the overall optimisation solution under the condition of the floating material flow matrix, so as to achieve the goal of optimising the total MHC in the entire production process. As the new model introduces more variables and intermediate parameters, a two-stage solution method is previously required, which greatly increases the time to solve the problem. This paper proposes a targeted meta-heuristic algorithm optimisation method combining the advantages of tabu search algorithm and harmony search algorithm, which simplifies the solution phase of calling the precise solver in the two-stage algorithm of row facility layout problem, improves the problem solving efficiency, and makes the solution of large-scale problems become possible. The proposed model is verified through Lingo software, and then the model and the hybrid algorithm in the MATLAB environment are verified with each other. Finally, the proposed simplified algorithm is utilised to solve the large-scale problems that could not be solved by the two-stage algorithm before.

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%.

The cost analysis of material handling in Chinese traditional praying paper production plant

Chinese traditional praying paper industry is an industry which produced Chinese traditional religion praying paper. This kind of industry is rarely examined since it was only in Small and Medium Enterprise (SME’s- form). This industry produced various kinds of Chinese traditional paper products. The purpose of this research is to increase the amount of production, reduce waiting time and moving time, and reduce material handling cost. The research was conducted at prime production activities, consists of: calculate the capacity of the material handler, the frequency of movement, cost of material handling, and total cost of material handling. This displacement condition leads to an ineffective and inefficient production process. The alternative was developed using production judgment and aisle standard. Based on the observation results, it is possible to reduce displacement in the production. Using alternative which by-passed displacement from a rolled paper in the temporary warehouse to cutting and printing workstation, it can reduce material handling cost from 2.26 million rupiahs to 2.00 million rupiahs only for each batch of production. This result leads to increasing of production quantity, reducing waiting and moving time about 10% from the current condition.

ANALISIS TATA LETAK FASILITAS DENGAN MENGGUNAKAN METODE ACTIVITY RELATIONSHIP CHART PADA INDUSTRI MEBEL BAMBU KARYA MANUNGGAL YOGYAKARTA

Plant layout or facilities layout is to fix regulate facilities layout with consider material handling flow. In this research on Bamboo Furniture Industry Karya Manunggal Yogyakarta show less precisely placement of production facilities and flow material resulting in the total distances of material handling becomes long and induce the total cost of material handling becomes high.Improvement of facilities layout performed with qualitative methods ARC (Activity Relationship Chart). This matter do for obtain a new layout with minimum total distances of material handling and minimum total cost of material handling. In this research use POM QM Software for validating total distances of material handling.Analysis result and designing facilities layout is a new layout with Rectilinear Distance method, The initial movement distances is 1.922,9 m become 1.832,35 m or have a reduction distances 4,94 % from initial layout. While for the initial total cost of material handling is Rp 200.135,6 become Rp 199.745,9 or have a reduction cost 0,19% from initial layout. Existence a new layout based on ARC be expected on the production floor of Bamboo Furniture Industry Karya Manunggal Yogyakarta.

An efficient algorithm for unequal area facilities layout planning with input and output points

ABSTRACTThe facility layout problem is to determine a layout design of facilities so as to minimize a total material handling cost (TMHC). In this paper, unequal area rectangular facilities with fixed dimensions are considered. Each of them has an input and output (I/O) points which can be located within or on the boundaries of facility. On the continual plane, facilities must be placed without overlaps. A two-heuristic algorithm is proposed to deal with this kind of problem. The first step is based on a construction method which places facilities sequentially. A median method is modified to set the position of facility. The second step improves a result of the first step. A facility group which can be moved horizontally or vertically without incurring an overlap is constituted and a group movement is done when it reduces a TMHC. Computational experiments show the proposed algorithm produces comparable quality of layouts to previous research within much shorter time.

Designing a cellular manufacturing system considering decision style, skill and job security by NSGA-II and response surface methodology

Cell formation is a traditional problem in cellular manufacturing systems that concerns the allocation of parts, operators and machines to the cells. This paper presents a new mathematical programming model for cell formation in which operators’ personality and decision-making styles, skill in working with machines, and also job security are incorporated simultaneously. The model involves the following five objectives: (1) minimising costs of adding new machines to and removing machines from the cells at the beginning of each period, (2) minimising total cost of material handling, (3) maximising job security, (4) minimising inconsistency of operators’ decision styles in cells and (5) minimising cost of suitable skill. On account of the NP-hard nature of the proposed model, NSGA-II as a powerful meta-heuristic approach is used for solving large-sized problems. Furthermore, response surface methodology (RSM) is used for tuning the parameters. Lastly, MOPSO and two scalarization methods are employed for validation of the results obtained. To the best of our knowledge, this is the first study that presents a multi-objective mathematical model for cell formation problem considering operators’ personality and skill, addition and removal of machines and job security.

A hybrid approach for selecting material handling equipment in a warehouse

Warehouse operations are closely related to material handling activities. Loading, unloading, transporting and picking material constitute a huge part of the activities. In order to handle material properly as well as to contribute value to the material, the operator and the environment, utilizing Material Handling Equipment (MHE) is required. The selection of proper MHEs requires great focus since its consideration is linked to mutli-criteria and multi-objective decision making problems. Here, a hybrid method is proposed to address the MHE selection problem. An approach that integrates the entropy based hierarchical fuzzy Technique for Order Preference by Similarity to an Ideal Solution (TOPSIS) and Multi-Objective Mixed Integer Linear Programming (MOMILP) is used for seeking the best alternative. The evaluation of alternatives is performed based on both subjective and objective criteria. Subjective weights are derived from a fuzzy Analytic Hierarchy Process (AHP). To deal with objective criteria, the entropy method is adopted to determine the weights, and the integrated weights are also calculated. The alternatives are rated by using fuzzy TOPSIS. For final execution of the selection, an MOMILP model is developed incorporating two goals, namely to minimize the disadvantage of material handling operation and to minimize the total cost of material handling. The AUGMented E-CONtraint method (AUGMECON) is used to solve the model. A case study is given to illustrate the method. The results show the effectiveness of the hybrid method in complex decision making.

An efficient local search heuristic for the double row layout problem with asymmetric material flow

The double row layout problem (DRLP) consists of arranging a number of rectangular machines of varying widths on either side of a corridor to minimize the total cost of material handling for products that move between these machines. This problem arises in the context of many production environments, most notably semiconductor manufacturing. Because the DRLP contains both combinatorial and continuous aspects, traditional solution approaches are not well suited to obtain solutions within a reasonable time. Moreover, previous approaches to this problem did not consider asymmetric flows. In this paper, an effective local search procedure featuring linear programming is proposed for solving the DRLP with asymmetric flows (symmetric flows being a special case). This approach is compared against several constructive heuristics and solutions obtained by a commercial mixed integer linear programming solver to evaluate its performance. Computational results show that the proposed heuristic is an effective approach, both in terms of solution quality and computational effort.

A corrected formulation for the double row layout problem

This paper presents a corrected formulation to the mixed integer programming model of the double-row layout problem (DRLP), first proposed by Chung and Tanchoco (2010, The double row layout problem. International Journal of Production Research, 48 (3), 709–727). In the DRLP, machines are placed along two rows of a corridor, where the objective is to minimise the total cost of material handling for products that move between these machines. We highlight the errors in the original formulation, propose corrections to the formulation, and provide an analytical validation of the corrections.

Layout Design for Efficient Material Flow Path

Traditionally the design of physical layout of the manufacturing system (Inter-cell layout) and subsequently the design of Material Handling System (MHS) is being carried out in isolation. In this work an attempt is made to concurrently design Inter -Cell Layout and the MHS using a Genetic Algorithm based methodology for a Cellular Manufacturing System (CMS) environment under open field configuration. The proposed algorithm is employed to simultaneously optimize two contradicting objectives viz. 1. Total material handling cost (TMHC) 2.Total corner score (TCS). The algorithm is tested on four different bench mark layouts and with different initial problem data sets. It is found that the proposed algorithm is able to produce satisfactory solutions consistently within a reasonable computational limit.

An integrated synthetic value of fuzzy judgments and nonlinear programming methodology for ranking the facility layout patterns

In this paper, the goal is to incorporate qualitative criteria in addition to quantitative criteria to facility layout design (FLD) problem. To this end, we present an integrated methodology based on the synthetic value of fuzzy judgments and nonlinear programming (SVFJ–NLP). The facility layout patterns (FLPs) together with their performance measures of total cost of material handling are generated by a computer-aided layout-design tool, CRAFT. Also, the performance measures of second quantitative criterion (construction cost of width walls) are calculated by appraising these FLPs. The SVFJ is then applied to collect the performance measures related to qualitative criteria and finally, a non-linear programming (NLP) model is proposed to solve the FLD. Results obtained from a real case study validate the effectiveness of the proposed model.