Research on Simulation and Optimization of Facility Layout in Flexible Manufacturing Workshop

This study addresses the challenge of prolonged forklift repair times at PT Karya Mitra Teknik, a heavy equipment repair company, attributed to inefficient facility layout. Through field observations and stakeholder interviews, Activity Relationship Chart (ARC) and Analysis Allocation Diagram (AAD) methods were applied to identify inefficiencies and propose layout improvements. Results show a significant reduction in total repair area distance from 110 meters to 55 meters, indicating enhanced operational efficiency. The findings underscore the importance of optimizing facility layout in heavy equipment repair workshops to streamline operations and reduce repair turnaround times, offering practical implications for similar industries seeking cost-effective solutions. Highlights: 1. Efficient facility layout reduces repair area distance.2. ARC and AAD methods streamline resource allocation.3. Optimal layout enhances operational efficiency, reduces turnaround times. Keywords: Facility Layout Optimization, Heavy Equipment Repair, Operational Efficiency, Activity Relationship Chart (ARC), Analysis Allocation Diagram (AAD)

Appropriate selection of facility layout methodology for designing or improving a layout of a plant is very crucial and can have a high impact on the success of a plant. Continuous improvements in layout can increase productivity, reduce wastage and improve the quality and safety of the plant. A case study on improvement done in electronic product manufacturing plant is elaborated in this chapter. The plant layout is re-organized from a product-based layout to a hybrid of product- and process-based layouts. This is an observation-based study which resulted in significant improvement in material flow in the plant, improvement in productivity, and improvement in quality and safety in the plant. This study suggests involving continuous improvement in layout and measuring the impact of changes. Facility layout should be part of continuous improvements. Being a case study approach for improvement in layouts, this study highlights the credibility of applications of improvement in layout in the real-world working environment.

An evolutionary optimal green layout design for a production facility by simulated annealing algorithm

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%.

Multiple-method analysis of logistics costs

Based on the study of the unidirectional loop layout, this paper analyzed the necessity of genetic algorithm to the workshop layout optimization. To minimize transportation travel, the mathematical model of the unidirectional loop workshop facility layout was set up, using the niche genetic algorithm with introduction of penalty function and elite reservation strategy to accomplish the facility layout optimization. Through the calculation of the example, the feasibility and effectiveness of this algorithm in facility layout optimization design is verified.

One of unique characteristics of Thai jasmine rice is its aroma, which can easily reduce in various conditions during post-harvesting activities, especially in rice milling stage. This study aims to investigate logistics cost analysis of the rice mill of Kasetwisai Agricultural Cooperative, Ltd. by using activity based costing (ABC) method and to define key activities for the improvement of the rice aroma loss reduction. The results show that the activity that has the highest logistics cost is warehousing at 26.52%, followed by material handling at 24.27%, transportation at 12.33% and packaging at 10.84% of the total logistics cost, respectively. The total logistics cost per unit of the rice mill is about 4.52 baht/kg. Findings from an in-depth interview revealed that warehousing and transportation can be major activities influencing aroma loss in jasmine rice. To reduce the aroma loss in a cost effective way, the Kasetwisai Agricultural Cooperative, Ltd. should focus on storage time and temperature in warehousing and transportation systems. In addition, the collaboration of the rice miller with supply chain partners should be encouraged to cut the logistics cost and to improve the quality of rice. Keywords: Activity Based Costing; Aromatic Rice; Jasmine Rice; Logistics Cost; Value Chain

Agifa Roti is one of the small and medium enterprises (SMEs) engaged in the food industry, located in Warungboto, Umbulharjo District, Yogyakarta City, Special Region of Yogyakarta. The products produced are in the form of basic ingredients for sweet bread, in the production process it is still traditional without using the help of machines only during the baking process using a gas-fueled oven and mixer to make dough. facing waste constraints in the sweet bread production process, especially in waiting activities (31.07%) and transportation (8.90%). This waste is caused by the less than optimal layout of facilities, with a distance of movement between work stations reaching 810.99 cm. This study aims to identify waste, reduce waste, and increase production efficiency through the application of the Lean Manufacturing method with the Value Stream Mapping (VSM) approach including the calculation of Material Handling Costs (OMH) to assess cost efficiency. Research methods related to cycle time, lead time, changeover time, and facility layout. Based on the research results, it shows that the application of the Lean Manufacturing method with the VSM approach is able to reduce the distance of movement between work stations by 29.2%, production cycle time by 61.2%, and material handling costs significantly, thereby increasing efficiency, reducing waste, and providing real benefits for the productivity and competitiveness of Roti Agifa MSMEs and similar MSMEs.

This research tries to shed light on precise values of logistics costs that so far undisclosed. The values are important for every project planners to evaluate, control and monitoring, and especially imperative for procurement activities. Tender, bidding, and defining the scope of contracts and value can be well organized without time-consuming. This research uses methodology previously developed by Subiyanto (2020a) and discussed only a few particular and directly related to the logistics. The model had been decomposed by utilizing path analysis and the data had been regressed to define variables as the most inflator for logistics. The findings are total logistics costs in Indonesia generally at around 14.6% to total costs of investment. It consists following of insurance cost 0.11%, costs for customs clearance 6.52%, foreign logistics costs 6.62%, domestic manufacture 0.47%, and domestic logistics costs 0.89%. This research is not discussing logistics costs relating to human resources, human travelling, and internal logistics conducted by vendors or contractors as the scope included counted within their procurement contract. These results are important as guidance for project planners, controllers, and other parties to prepare costs more precisely. Negotiating to the banks will be easier as the more precise amount of budgets had been estimated. Due to the important values that have been identified, there will help transparency and governance conducting the projects. Procurement processes involving societies are more objective and better. This is a novelty finding as previous researchers have not decided yet.

Because of the competition of the medical market and the importance of the operaing theatre (OT), the OT process efficiency becomes a hot spot problem in hospital management. The OT facility layout is not only a problem about cost reduction, but also a great contribute to the efficiency of OT process. However, the facility layout optimization of OT was always ignored in the past decades. In order to become more competitive in the medical market, the facility layout of OT should be considered as an essential section in early design phase. To overcome these problems, this paper proposed a approach for designing and optimizing the facility layout of OT in hospitals. First, systematic layout planning (SLP) is applied to design the layout of OT based on the logistics and non-logistics relationships. The SLP is a tool which is used to arrange a workplace in a plant by locating two areas with high frequency and logical relationships close to each other. After that, fuzzy constraint theory is proposed for comprehensively evaluate the layout schemes. Fuzzy constraint theory uses objective function and constraint conditions for solving the problem which involves uncertainty. After designing and optimizing the facility layout of OT in Shanghai East Hospital, we can get the optimal layout plan. The aim of this study was development a new approach to design and optimize the facility layout for OT. This research results are able to help the hospital managers to adopt more modern management approaches in every day practise.

With the development of society, market competition becomes increasingly fierce, companieswant to achieve stable development and efficient profits, strengthen its internal managementand cost control are important measures to enhance the economic efficiency of enterprises. In business management and cost control, statistical work plays an important role, which cannot only reduce the operating costs in enterprise management, clarify receipts and disbursements of enterprise, while also has an important significance for improving enterprise management and cost control quality, and promoting the healthy development of enterprises. This study analyzes the development cost control situation of enterprise, the application of statistics in business management and cost control, and finally with examples to have detailed in-depth analysis of the statistical applications in business management and cost control, for reference.

Purpose – In transportation and distribution systems, the shipment decisions, fleet capacity, and storage capacity are interrelated in a complex way, especially when the authors take into account uncertainty of the demand rate and shipment lead time. While shipment planning is tactical or operational in nature, increasing storage capacity often requires top management’s authority. The purpose of this paper is to present a new method to integrate both operational and strategic decision parameters, namely shipment planning and storage capacity decision under uncertainty. The ultimate goal is to provide a near optimal solution that leads to a striking balance between the total logistics costs and product availability, critical in maritime logistics of bulk shipment of commodity items. Design/methodology/approach – The authors use simulation as research method. The authors develop a simulation model to investigate the effects of various factors on costs and service levels of a distribution system. The model mimics the transportation and distribution problems of bulk cement in a major cement company in Indonesia consisting of a silo at the port of origin, two silos at two ports of destination, and a number of ships that transport the bulk cement. The authors develop a number of “what-if” scenarios by varying the storage capacity at the port of origin as well as at the ports of destinations, number of ships operated, operating hours of ports, and dispatching rules for the ships. Each scenario is evaluated in terms of costs and service level. A full factorial experiment has been conducted and analysis of variance has been used to analyze the results. Findings – The results suggest that the number of ships deployed, silo capacity, working hours of ports, and the dispatching rules of ships significantly affect both total costs and service level. Interestingly, operating fewer ships enables the company to achieve almost the same service level and gaining substantial cost savings if constraints in other part of the system are alleviated, i.e., storage capacities and working hours of ports are extended. Practical implications – Cost is a competitive factor for bulk items like cement, and thus the proposed scenarios could be implemented by the company to substantially reduce the transportation and distribution costs. Alleviating storage capacity constraint is obviously an idea that needs to be considered when optimizing shipment planning alone could not give significant improvements. Originality/value – Existing research has so far focussed on the optimization of shipment planning/scheduling, and considers shipment planning/scheduling as the objective function while treating the storage capacity as constraints. The simulation model enables “what-if” analyses to be performed and has overcome the difficulties and impracticalities of analytical methods especially when the system incorporates stochastic variables exhibited in the case example. The use of efficient frontier analysis for analyzing the simulation results is a novel idea which has been proven to be effective in screening non-dominated solutions. This has provided the authors with near optimal solutions to trade-off logistics costs and service levels (availability), with minimal experimentation times.

This paper presents an analysis on logistics facilities layout of manufacture enterprise and the application of intuitionistic fuzzy sets as an evaluation to optimise logistics facilities layout problem. In this paper, systemic layout planning (SLP) has been employed to design the logistics facilities and determine the optimal location of each warehouse. Innovatively, this paper introduces the intuitionistic fuzzy sets (IFSs) to evaluate logistics facilities layout comprehensively after we formed the facilities layout plan. Most noteworthy is that a broad and detailed two-stage index system of logistics facilities layout has been established including the aspect of economy, efficiency, adaptability, security and environment. Though the comprehensive assessment of production logistics facilities layout is good (G), there exists optimal spatial to improve logistics efficiency. Therefore, we propose a new improved logistics facilities layout. After manufacture enterprise implements the improved logistics facilities layout, its transportation become more unobstructed, waiting time has been reduced and cost of logistics has been decreased consequently.

With the development of domestic economy and the change of consumption patterns, especially the boom in online shopping, the logistics industry has a dramatic development in our country. Nevertheless, the logistics enterprises are still facing some issues such as high service cost, lack of competition, etc. Previous study on the cost of logistics enterprises concentrated more on the theoretical analysis.This study is based on the study of the logistics costs、ratio using and contrast analysis to analyze the cost of main operation、period charge and main business income and according to the financial statement of 15 logistics listing enterprises,discuss the reasons of the high cost of logistics enterprises. Current situation of logistics cost In 2012, our country's logistics costs as a share of GDP at 17.8%. In 2013, it did not decline, is still around 18%, essentially flat with 2012. While at the same time, the developed countries, such as America, Japan, Germany, the total social logistics costs accounted for the proportion of the national GDP is respectively 8.5%, 8.7% and 8.3%. The BRIC countries, such as India and Brazil, were respectively 13% and 11%. The world average level is at 11.2%.Therefore, the development and the operation efficiency of China's logistics industry is far behind the developed countries and the other BRIC countries, even behind the average level of the world. Table1 the comparison of China's logistics cost data in 2012 and 2013 Unit: trillion RMB Project

Development of an effective logistics infrastructure for companies contributes to ensuring their effective work, directly affects financial performance and requires the establishment of a management and accounting system for logistics costs. Classifying and registering logistics costs becomes more important in this regard. At this stage of Ukrainian accounting practice, there are challenges for logistics costs accounting such as their identification and registration. Methodological basis of study among different logistics concepts (concept of general logistics costs, concept of reengineering business processes in logistics, concept of an integrated logistics strategy, concept of supply chain management) was total logistics costs concept or the concept of full value as well as process-oriented approach. In the work, the generalization and formalization of existing approaches to the logistics costs accounting was made. Feasibility of using a process-oriented approach among other approaches (absorption costing, direct costing target costing, kaizen costing, etc.) were substantiated. The algorithm of identification and registration of logistics costs for Ukrainian enterprises was proposed. It is based on such inclusion in the relevant economic process (supply, production, sales and administration of logistics processes) and the use of a new consolidated account 29 “Logistics costs”. This authors’ approach to solving the problem of identification and registration of logistics costs for accounting purposes allows to optimize and increase the informativeness of accounting logistics costs reflection in Ukrainian accounting practice.