Optimization of plant layout & implementation of 5S

Abstract

The objective of this thesis is to improve the production floor layout of a manufacturing firm using systematic layout planning (SLP) and implement 5s. This project is conducted at NEXA PVT. LTD. MUMBAI various Aviation and Marine equipment’s parts manufacturing company located in at New panvel. The major problem faced by the company is inventory control, store management, poor utilization of space, poor material handling and safety hazards. There is high flow intensity between departments which have high interrelationship. This leads to high travelling time and high travelling cost which in turns decreases overall productivity of the company. An alternative layout is proposed using the 11 steps in Systematic Layout Planning, which is a systematic way of generating layout alternatives. The proposed layout involves transferring the departments which have high interrelationship close to each other. The proposed alternative layout is evaluated later. The layout is chosen based on the performance measures which have the most significant improvement, which are total travel distance, total travel time, output, average resource utilization, total average WIP level, total average waiting time and total time spent in manufacturing certain product either job order or in batches.