Abstract:
The objective of this thesis is to improve the facility layout of manufacturing firm
using Systematic Plant Layout (SPL) or Systematic Layout Planning (SLP) and implementation
of 5S. This project is conducted at HITESH MECHANICAL PVT.
LTD, RABALE where various pressure vessels, agitated vessels, chemical reactors,
chimneys, feed gas preheater, galvanizing tank, etc. like products are manufacturing
company located at New Mumbai. The major problem faced by this firm is inventory
control, scrap management, store management, poor utilization of space, poor material
handling. There is high flow intensity between the departments which have high
interrelationship. This leads to high travelling time which increases the travelling
cost which in turn decreases the overall productivity of the company.
An alternative layout is proposed by using the steps in Systematic Plant Layout,
which is the systematic way of generating layout alternatives. The proposed layout
involves optimizing the departments which have high interrelationship and close to
each other. The proposed alternative layout is further evaluated by using Pugh matrix.
The layout is chosen based on the performance measures which have the most
significant improvements in the facility. Later after implementing the modified layout
5S is also implemented simultaneously based on the steps as discussed in this
thesis to manage the facility.
Keywords: Systematic plant layout, algorithms, material flow, CRAFT, CORELAP,
from-to chart, activity relationship chart, fabrication, Pugh matrix, 5S, lean manufacturing,
quality, waste.
