Improving the Layout of Production Facilities Using the Systematic Layout Planning and BLOCPLAN Algorithm

Abstract

The research focuses on resolving production floor problems which affect an electronics manufacturing facility that produces stabilizers and starters and casings by using a job-shop production system. The lack of structured layout design has caused materials to travel through long routes which also require multiple returns across all three product manufacturing lines. The facility layout received its redesign through Systematic Layout Planning (SLP) and the BLOCPLAN algorithm. The research team used From-to Chart (FTC) and Activity Relationship Chart (ARC) and Activity Relationship Diagram (ARD) and Space Relationship Diagram (SRD) tools to develop three different layouts which they assessed by measuring total distance and backtracking distance and backtracking percentage. Proposed Layout 3 achieved better results than the original layout by reducing material movement distance by 36.35 meters and backtracking distance by 25.08 meters and backtracking percentage by 7.73 percent which showed the value of the SLP–BLOCPLAN framework for multi-product manufacturing facilities.