Process analysis and optimal facility layout planning in manufacturing systems

Abstract

In this article, it is emphasized that the process analysis for companies is carried out by using the DISCO process mining program and the results are interpreted and developed. In the light of machine and worker occupancy information obtained as a result of process analysis, imbalances, if any, are detected. These imbalances are resolved by arranging job assignments. Another information that we obtain is the time elapsed until the processing of any workpiece on a machine is finished. This time consists of the time elapsed between the machines and the waiting time in the queue of the machine to be processed. The waiting time in the queue of the machine will be improved by adjusting the workload balance of the machines and the transportation times will be improved by creating the best plant layout suitable for the process. As a result, the facility layout of the factory was made considering the functional grouping. In the study, a layout is designed in accordance with the workflow of the products. With this newly designed plan, it has been determined that the products can be produced by covering 50% less transport distance. In addition, the workload imbalances of the machines and workers were corrected by changes in job assignments. This has reduced the cycle time of a product by eliminating bottlenecks at the factory.