SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 56
Rearrangement of Machines on Shop Floor using Genetic
Algorithm Vikram Singh
a, Sanjeev Verma
b
a, Student, Department of Mechanical Engineering
PCET, India
b, A.P, Department of Mechanical Engineering
PCET, India.
Abstract: The objective of this paper is to reduce
movement distance in order to increase the
productivity and decrease the cost of component and
this can be done if we decrease the characteristics of
layout using Genetic Algorithm. This project is
conducted at Unitech Machines Limited.
Manufacturing company located in Saharanpur. The
major problem faced by the company is high
bottleneck. The one more problem that also occurred
in the Existing layout is the high movement distance
by going through by pass of machine is also removed
by designing the new shortest path from one machine
to another machine in according to the sequence of
operations. In this we have installed a PAM machine
in the shop floor that reduces the movement time and
movement distance from company to vendor and then
return.With the implementation of proposed layout
the floor space is utilized efficiently and properly and
with the pathways, every machine is accessible
through overhead crane. Genetic Algorithm programs
include a number of parameters including the
probabilities of crossover and mutation, the
population size and the number of generations. A full
factorial experiment was performed to identify the
best configuration. The number of generations was
the only statistically significant factor. When the
layout was treated as a green-field problem the total
rectilinear distance travelled was reduced by 70% and
the population size, the number of generations and
the probability of crossover were statistically
significant. The results were compared with the
Company‟s layout and the best layout that could be
generated randomly. With better placement of
machines and path ways, plant is capable of taking
maximum production at minimum labour cost. The
difference between Existing and new material
distance shows reduction in the movement distance
of the components. Material handling distance among
the machines is reduced by 70.84%.
1. INTRODUCTION
Plant layout planning refers to the arrangement of
physical facilities such as machines, equipment,
tools, furniture etc. in such a manner so as to have
quickest flow of material at the lowest cost and with
the least amount of handling in processing the
product from the receipt of raw material to
the delivery of the final.Facility layout problems
(FLPs) concerning space layout optimization have
been investigated in depth by researchers in many
fields, such as industrial engineering, management
science, and architecture. Layout design
investigations have been helped by recent advances
in computing science and also by increased
understanding of the methods used for developing
mathematical models. The FLP has applications in
both manufacturing and the service industry.
There are mainly four types of plant layout
Product or line layout
Process or functional layout
Fixed position or location layout
Combined or group layout
COMPANY PROFILE:-
Unitech Machines Limited incorporated in the year
1986 is a leading organization specializing in the
field of Turnkey Installation throughout the country
and are well equipped with a team of dedicated
engineers in the field of design, procurement,
project management & erection and commissioning
of systems. UML undertake complete design,
engineering, fabrication, supply, installation,
testing commissioning of utility piping system,
firefighting system, fire detection and alarm
system, and tank ages.
2. Literature
Jin-Ling Lin a, Bobbie Foote et al. [1996] The
problem of assigning positions to unequal fixed size
and shape departments within a given plant area has
prompted numerous research efforts in recent years.
Most of the published papers discuss techniques that
place departments in such a way that the local cost of
material flow between departments is minimized.
Many of these techniques assume that there exists at
least one-feasible layout.
M. Hasan Imam and Mustahsan Miret al. [1998]
proposed an analytical technique to optimize the
layout of building-blocks of unequal areas in a
continuous plane. A construction-cum-improvement
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 57
type algorithm is introduced in which the optimum
position of each block was determined by piece wise
one-dimensional search on the boundary formed by
the cluster of previously placed blocks. The search
process was dynamic so that all boundary blocks
were continually moved to their optimum positions
until no more improvement was possible. The
technique was implemented in a computer program
which was fully automated and did not require any
user interaction to obtain the optimal layout.
C. M. L. Castell, R. Lakshmanan,et al. [1998] The
layout of chemical facilities is an activity that is
largely carried out by the human designer. Few
methods exist for optimizing layout. Difficulties in
formulating the problem as a mathematical program
stem fromnon- convexities as well as from non-
differentiable cost functions.
Christian Hicks [2006] proposed a Genetic
Algorithm optimisation method that had been
developed which could be applied to a set of
manufacturing cells or to an entire manufacturing
facility. The approach could be used for either green
field or brown field layout problems. The model was
tested using a large data set from a collaborating
capital goods company. Genetic Algorithm programs
include a number of parameters including the
probabilities of crossover and mutation, the
population size and the number of generations.
Lou Y. Liang and Wen C. Chao [2008] proposed
that the facility layout problem was concerned with
finding the optimal facility arrangement in the
existing layout. From many artificial intelligence
searching methods, the tabu search was widely
applied to the optimization problems. In this paper,
the efficient strategies of tabu search algorithm had
been developed to improve the layout in the facility
layout problem. In order to improve the layout
results, the strategies in the different intensification
and diversification procedures were proposed in this
study.
Wei Xie et al. [2008] proposed a continuous facility
layout (CFL) models to address the limitations by
modelling facilities as geometric entities and
searching for an optimal two-dimensional packing.
However, solving these proposed models becomes
dramatically harder: finding optimal layouts for these
models was beyond reach of current optimization
techniques, except for tiny instances. In this paper,
they presented several important theoretical results.
Christian Díaz-Ovalle et al. [2010] proposed a new
approach to determine the optimal distribution of
process facilities was presented in this paper. The
formulation considers a set of facilities already
installed in a given land and a new set of facilities to
be accommodated within the same land. In addition,
it was considered that a set of facilities either
installed or to be laid out presents the possibility of
toxic release. Based on previous analysis, the worst-
case scenario implied calm wind and stable
atmospheric condition. Since these conditions tend to
exist during several days of the year, the proposed
model was formulated assuming these deterministic
values for wind and atmospheric conditions.
IrajMahdavia et al. [2013] proposed a new
integrated mathematical model considering cell
formation and cell layout simultaneously. The goal of
their model was to group similar parts and
corresponding different machines in same cells.
Machines sequence in each cell and cell positions is
also specified in the system.
3. PROBLEM FORMULATION AND
OBJECTIVE
3.1 EXISTING LAYOUT
Certain information about materials and the process
of manufacturing which has been selected is
important in developing a layout. In a layout problem
involving a product already in production,
information on the process may be obtained from the
records of the appropriate department within the
plant. When a new product is to be made in the
proposed layout, such information must still be
obtained, but it will probably have to be developed
by layout man [9]. The existing layout of Press Shop
of UM Ltd. is shown in Figure 3.1 having the
dimension of length 90 feet and breadth 64 feet. In
this length is along the west-east direction. Thus the
total area of the shop floor is 5760 square feet and the
total space occupied by the machines is nearly 807
square feet. This is the very small utilization of
available space and there is a maximum movement of
material like movement of raw or finished product
from one machine to another machine. In this layout
the total available machines is nearly 28 with store
room facility. These machines with their dimensions
are shown in the given table 3.1 and the arrangement
is shown in the figure 3.1 (Exiting Layout of Press
Shop). From the study of this layout we find that
there will be need to utilise the available space.
Utilisation of this space can be done by designing
good layout and minimising the movement time and
movement distance.
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 57
Figure 3.1: Existing Layout of Press Shop
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 58
Table 3.1 : Machines available on Shop floor
SERIAL NO. MACHINESNAME MACHINES
CODE
DIMENSIONS(L×B)
FEET
1 Hydraulic Press P1 3×3
2 Hydraulic Press P2 3×3
3 Hydraulic Press P3 3×3
4 Hydraulic Press P4 3×3
5 Radial Drilling DM 6×6
6 Mechanical Shear MSM 5×5
7 Break Press BP 5×5
8 Mechanical Break Press MBP 7×5
9 NC-Break Press NBP 7×5
10 Shear Press SP 5×5
11 Mechanical Shear Press MSP 7×5
12 NC-Shear Press NSP 7×5
13 Muller Machine MM 6×3
14 Die Rack DR1 5×3
15 Die Rack DR2 5×3
16 Panel Rolling PR 15×4
17 Cold Section Rolling SR1 15×4
18 Cold Section Rolling SR2 15×4
19 Pallet PA1 15×4
20 Pallet PA2 15×4
21 Pallet PA3 15×4
22 Power Press PP1 4×4
23 Power Press PP2 4×4
24 Power Press PP5 4×4
25 Store S1 4×4
26 Store S2 4×4
27 Store S3 4×4
28 Store S4 4×4
TOTAL AREA OCCUPIED (square feet) 807
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 59
Table 3.2:Operation Chart of Press Shop
From the available data of these tables we find that
there will be a need to reduce movement time and
movement distance in order to increase the
productivity and decrease the cost of component and
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 57
this can be done if we decrease of the characteristics
for designing layout.
This ratio indicates the percentage of the amount of
rectangular-shape machines compared with the
number of square-shape machines as in equation (1).
It relates to P/D point depending on the orientation.
Apply Genetic Algorithm (GA) to examine machine
selection rules proposed inthis work for minimizing
the total handling distance of material flows between
machines and alsothe manufacturing cost of product.
4. Methodology
4.1 PROGRAMMING OF GENETIC
ALGORITHM
Apply Genetic Algorithm (GA) to examine machine
selection rules proposed in this work for minimizing
the total handling distance of material flows between
machines; and also the manufacturing cost of
product.
ii) Investigate the influence of rectangular-to-
square (R/S) ratios associated with machine
dimension on the efficiency of layout design.
Designing the rotatable machine layout followed by
Genetic Algorithm process for solving MLD problem
and its pseudo-code. The experimental results are
presented in next section. Finally, the conclusions are
drawn in the last section.
4.1.1 Layout design of rotatable rectangular
machines
Design task of rectangular machine layout is
concerned with the placement of machines into a
limited shop floor area (Length: FL and width: Fw)
having gap (G) between machines. In multiple-row
environment, predefined machines are arranged row
by row, from left to right, starting at the first row
(R1) and respecting FL and the gap (G).). The design
usually constrains by.
M is a number of machines, i and j are machine
sequences (i and j = 1, 2, 3,…, M), fijis frequency of
material flow between machines i and j, dijis the
distance between machines i and j (i ≠ j).
5. RESULTS AND DISCUSSION
5.1 LAYOUT ALTERNATIVE (PROPOSED)
the new layout of press shop of UM Ltd. having the
same dimension that in Existing layout also having
the same area but there is some change in the
movement path of material and some change in the
layout are shown in given figure 3.1 and here the area
of movement path is 2014 square feet. And the area
occupied by the machines is 1043 square feet. Then
the total area used by machines and movement path is
3057 square feet and total available area in shop is
5760 square feet and the remaining area is used as the
allowance given around the machines and working
persons in order to achieve good working
environment. Here from the figure 3.3 the yellow
block shows the movement path of material and tools
with the help of overhead crane. Figure 5.1 shows the
new layout of press shop helps in removing the
bottleneck from the section rolling machine by
adding a new cold rolling SR3 machine. By adding
this machine at the given location shown in the layout
improves the production and minimise the waiting
time. The one another problem occurred with
Existing layout is cutting of more than 8 mm. thick
sheet is also removed in this new layout by installing
the required PAM machine. This machine can be able
to cut or bend more than 8 mm thick sheet. Thus by
installation of PAM machine in this shop reduces the
movement time and movement distance from
company to vendor and then return. The one more
problem that also occurred in the Existing layout is
the high movement distance by going through by
pass of machine is also removed by designing the
new shortest path from one machine to another
machine in according to the sequence of operations.
By minimising the movement distance the movement
time is also reduced that will help in reducing the
cost of product and increasing the production.
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 56
Figure 5.1 Alternative Layout
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 57
Table 5.1: Present Machines Available with their occupied space on shop floor
SERIAL NO. MACHINE
NAME
MACHINE CODE DIMENSION(L×B)
1 Muller Machine MM 6×3
2 Die Rack DR1 5×3
3 Die Rack DR2 5×3
4 Hydraulic Press P1 3×3
5 Hydraulic Press P1 3×3
6 Hydraulic Press P3 3×3
7 Radial Drilling Machine DM 6×6
8 Plasma Arc Machine PAM 12×6
9 Mechanical Shear Machine MSM 5×5
10 Hydraulic Brake Press HBP 7×5
11 NC-Brake Press NBP 7×5
12 Hydraulic Shear Press HSP 7×5
13 NC-Shear Press NSP 7×5
14 Store 1 S1 4×9
15 Store 2 S2 4×9
16 Section Rolling(cold) SR1 15×4
17 Section Rolling(cold) SR2 15×4
18 Section Rolling(hot) SR3 15×4
19 Panel Rolling PR 15×4
20 Pallet PA1 15×4
21 Pallet PA2 15×4
22 Pallet PA3 15×4
23 Pallet PA4 15×4
24 Power Press PP1 4×4
25 Power Press PP2 4×4
26 Power Press PP3 4×4
27 Power Shear PS 4×4
28 Mechanical Press MP1 4×4
29 Mechanical Press MP2 4×4
30 Store S3 4×9
31 Store S4 4×9
TOTAL AREA OCCUPIED (square feet) 1028
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 58
Figure 5.2 Flow of Component Special and Regular Hat On Proposed Layout
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 56
5.3 COMPARISON OF MATERIAL
MOVEMENT
The comparative chart of material movement. In this
chart we compare the separate and total material
movement of all the components. The difference
between Exiting and new material distance shows
reduction in the movement distance of the
components. Thus after comparing the entire
components we have saved total 704 feet movement
distance. This movement distance saved is in moving
the one batch of the components. In one batch we can
take maximum of one coach components because of
the capacity of overhead crane. This crane is
designed only to take the component of one coach
because of some safety reason.
The given figures shows the comparative graph of
various components drawn on Existing layout and
proposed layout
Figure 5.3 Flow Graph of Component Special Hat
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 57
Figure 5.4 Flow Graph of Component Regular Hat
Figure 5.5 Flow Graph of Component Side Channel
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 58
i)
Figure 5.6 Flow Graph of Component Rain Gutter
Figure 5.7 Flow Graph of Component Floor Channel
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 59
Figure 5.8 Flow Graph of Component Section Panel
Table 5.2: Comparative Movement Chart
Sr. No. COMPONENT MOVEMENT(FEET) DISTANCE
SAVING
Existing Proposed
1 Special Hat 150 008 142
2 Regular Hat 160 008 152
3 U-Section 010 008 002
4 Side Channel 265 116 149
5 Rain Gutter 015 10 005
6 Floor Channel 262 140 122
7 Section Panel 167 010 157
Total Saving in the movement of material 729
.
SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 2 Issue 7 – July 2015
ISSN: 2348 – 8360 www.internationaljournalssrg.org Page 60
Table 5.3 Results of Comparisons
Sr. No. Saving Factor Saving per batch Saving per batch (%)
1 Travel distance(feet) 729 70.84
2 Time(minute) 3:30 10.29
3 Cost(Rs.) 292 70.87
CONCLUSIONS:
With the implementation of proposed layout
the floor space is utilized efficiently and properly and
with the
pathways, every machine is accessible
through overhead crane.
Material handling distance among the
machines is minimum.
With better placement of machines and path
ways, plant is capable of taking maximum
production at minimum labour cost.
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