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This Thesis addresses Factory Layout Problems, and reviews and evaluates the available layout techniques. Manufacturing as a system has been studied and reclassified for factory layout: space demands and spatial relationships have been considered as main principles of Factory Layout Planning. This forms a basis for the introduction of a new, more efficient Factory Layout Planning Methodology, denoted as SPACE MANAGEMENT. A new COMPUTER AIDED FACTORY LAYOUT PLANNING system is formulated as a tool for: - preparing 3-D templates of Work Station Modules and Equipment Modules; - drawing a requested interior of an industrial hall/bay in 3-D; - positioning any 'objects1 (spaces), via manual interactive programs i n 3-D; - automatic positioning of work stations and equipment in the bay, in 'technological' order (in 3-D), using an automatic positioning program, with a facility for: collision course finding(with objects within the bay), manual override for corrections, and finding an optimum size (width) of the bay. The resulting layout scene can be observed from any required Position and distance. The system includes a set of auxiliary programs for Manual Feeding of lines of work stations in 'technological' order and for basic capacity calculations. CAFLAP also opens a new way of economic evaluation of Projects and alternatives. CAFLAP is implemented in FORTRAN 77 and uses the Computer Graphics System PICASO.

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This research is devoted to the development of a multiobjective facility layout creation methodology. This methodology seeks to extend the scope of existing computerized and manual layout creation methods by capturing a greater level of both intuitive and quantitative inputs in a method applicable for moderate to large-scale problems. To do this, an extended theoretical basis for decision theoretic models applicable to layout design is described. Using these models as an evaluation basis, a new optimizing layout creation strategy is developed and a decision support system for its implementation is presented. The new layout creation method is computationally attractive, and based on extensive computational experience, is found to give better solutions than those generated by CORELAP. / Ph. D. / incomplete_metadata

This dissertation presents a methodology for the near optimal design of fixture layouts in multi-station assembly processes. An optimal fixture layout improves the robustness of a fixture system, reduces product variability and leads to manufacturing cost reduction. Three key aspects of the multi-station fixture layout design are addressed: a multi-station variation propagation model, a quantitative measure of fixture design, and an effective and efficient optimization algorithm. Multi-station design may have high dimensions of design space, which can contain a lot of local optima. In this dissertation, I investigated two algorithms for optimal fixture layout designs. The first algorithm is an exchange algorithm, which was originally developed in the research of optimal experimental designs. I revised the exchange routine so that it can remarkably reduce the computing time without sacrificing the optimal values. The second algorithm uses data-mining methods such as clustering and classification. It appears that the data-mining method can find valuable design selection rules that can in turn help to locate the optimal design efficiently. Compared with other non-linear optimization algorithms such as the simplex search method, simulated annealing, genetic algorithm, the data-mining method performs the best and the revised exchange algorithm performs comparably to simulated annealing, but better than the others. A four-station assembly process for a sport utility vehicle (SUV) side frame is used throughout the dissertation to illustrate the relevant concepts and the resulting methodology.

This dissertation presents a methodology for the near optimal design of fixture layouts in multi-station assembly processes. An optimal fixture layout improves the robustness of a fixture system, reduces product variability and leads to manufacturing cost reduction. Three key aspects of the multi-station fixture layout design are addressed: a multi-station variation propagation model, a quantitative measure of fixture design, and an effective and efficient optimization algorithm. Multi-station design may have high dimensions of design space, which can contain a lot of local optima. In this dissertation, I investigated two algorithms for optimal fixture layout designs. The first algorithm is an exchange algorithm, which was originally developed in the research of optimal experimental designs. I revised the exchange routine so that it can remarkably reduce the computing time without sacrificing the optimal values. The second algorithm uses data-mining methods such as clustering and classification. It appears that the data-mining method can find valuable design selection rules that can in turn help to locate the optimal design efficiently. Compared with other non-linear optimization algorithms such as the simplex search method, simulated annealing, genetic algorithm, the data-mining method performs the best and the revised exchange algorithm performs comparably to simulated annealing, but better than the others. A four-station assembly process for a sport utility vehicle (SUV) side frame is used throughout the dissertation to illustrate the relevant concepts and the resulting methodology.

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<p>This thesis is based on the present needs for the factory planning support, of which the most important ones are:</p><p>• A structured reuse of knowledge and support for industries. Because today the industry handbook in factory planning is not satisfying enough to support this complex process.</p><p>• Better methods to represent and communicate data between software within the factory layout area for easier data communication and thereby information access, exchange and reuse.</p><p>To support the factory planning, based on the mentioned needs, a mapping of the present factory planning process is made based on knowledge from industry and academy. Since the factory planning process is a huge and complex process that no one can handle by themself, a puzzle work is performed. Based on gathered information and knowledge an activity model is developed, to structure the data and information. The model gives a better overview on the actual course of events and in this way also “captures” the most important information to be represented for data exchange among different software applications and different people.</p><p>In this thesis the most important information in factory layout is gathered and structured in a concept model for factory layout. Since the concepts depend on the context in which they are used, it is extremely important to present every concept in its relationship with other related concepts within the area.  A general theory and state-of-the-art definitions in the area is presented and discussed for a factory planning information management system. An evaluation and discussion is made for the state-of-the-art software in the area of concern.</p>

Nowadays warehousing became one of the most important and critical part in supply chain systems due to the fact that it consumes a considerable part of logistic cost. Designing phase of warehousing system is the most important part in warehousing since most of the strategic and tactical decisions should be taken in this phase. Majority of academic papers are primarily analysis oriented and does not give a systematic method and techniques as a basis for warehouse redesign. So there is a need to develop a structured procedure that can be applied for different type of warehouses. Therefore the purpose of this thesis is to develop a process for redesigning production warehouses, and analyzing major problems during redesign steps. The thesis is designed as a case study, and a mix of quantitative and qualitative methods were used for data collection and data analysis. The methodology focuses around the warehousing process and redesign steps as described in the literature. Results of the thesis develop a seven steps procedure for redesigning of the production warehouse, also different problems and challenges are faced during redesign steps. It was tried to choose the best redesigning method which fit with the characteristics of the warehouse, in order to cover the space reduction of the warehouse with the consideration of existing facilities and reducing of cost. In addition, the performance of the current warehouse system was evaluated based on current design of the warehouse in order to avoid repeating of same mistake in redesign process. Storage assignment policy as one of the redesign steps was discussed and a framework for storage system of the components were suggested. The findings of the thesis to some extent can be applicable to other production warehouses. Further research is suggested for more specific results and new developed redesign methods for all types of warehouses.