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POM PPT

The document provides a critical review of facility layout design in fur manufacturing, emphasizing the importance of optimizing workflows and reducing costs. It discusses various methodologies, including empirical approaches, SLP, and value stream mapping, highlighting their advantages, disadvantages, and opportunities for enhancement. Proposed enhancements aim to improve efficiency, productivity, and quality by integrating lean principles and optimizing the entire production flow.

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Isha Gupta
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5 views

POM PPT

The document provides a critical review of facility layout design in fur manufacturing, emphasizing the importance of optimizing workflows and reducing costs. It discusses various methodologies, including empirical approaches, SLP, and value stream mapping, highlighting their advantages, disadvantages, and opportunities for enhancement. Proposed enhancements aim to improve efficiency, productivity, and quality by integrating lean principles and optimizing the entire production flow.

Uploaded by

Isha Gupta
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF or read online on Scribd
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CRITICAL REVIEW OF FUR MANUFACTURING COMPANY By: Diksha Sonthalia (2223054) Elizabeth Job (2223055) Gurpreet Sachdev (2223056) Himalika Mahindru (2223057) (sha Gupta (2223056) Jia Jasuja (2223059) Kashvi Bhartia (2223060) Table of contents Ol 02 03 04 OS Introduction t facility layout design Critical Review Proposed Enhancements Proposed Outputs Theoretical Concepts Introduction to facility layout design Facility layout design involves strategically arranging physical resources such as equipment, workstations, and storage areas within a manufacturing or service environment. The goal is to , A ‘optimize workflows, reduce costs, and improve efficiency while maintaining flexibility for changing production needs. Need for layout design: + Reduces unnecessary movement and transportation. © DA « Minimizes bottlenecks and waiting times. + Improves employee ergonomics and safety. + Enhances overall productivity and profitability Facility layout design, combined with lean methodologies like Kaizen, JIT, and waste ¢ elimination, cellular layout flows, visual managing tools, etc, create a robust system that fosters efficiency, agility, and continuous improvement for sustainable operational success. @ Critical View of Empirical Approach A practical method based on factory requirements and worker experience with factor analysis selection Advantages Simple and quick to implement using existing knowledge Heavily dependent on individual experience which may be biased Partially unification requirements Reduces distance between final phases Combines product and process layout features in U-shaped configuration while considering practical constraints achieves workst Disadvantages + Relies heavily on _ individual expertise, which may lead to inconsistent or suboptimal results if knowledge is lacking or biased. + Lacks a structured, repeatable methodology, making it difficult to adapt to changing needs or larger-scale operations. Opportunities + Can be enhanced by integrating basic analytical tools or frameworks (flowcharts, time and motion study etc) to reduce bias and improve repeatability + Offers a foundation for iterative improvement by combining it with more structured methodologies like SLP. + This integration allows organizations to leverage the best of both worlds— practicality and structure—while refining the layout over time through iterative improvements. Critical View of SLP structured engineering method using relationship charts and diagrams to optimize spatial relationships Advantages + Provides visual tools and structured analysis through relationship diagrams + Considers both qualitative and quantitative factors systematically ‘+ Moderate improvement in performance metrics + Achieved moderate improvements with 159% reduction in worker movement and €3,600 additional Key tool Relat Mapping Disadvantages ime-consuming and resource- tensive due to the complexity of analyzing multiple factors. + May lack flexibility to adapt dynamically to.—_real-time production changes or unexpected constraints Opportunities + Can be combined with digital tools like simulation software ( testing different layouts in virtual environments, providing detailed insights into potential inefficiencies that would be difficult to spot manually) to accelerate analysis and improve accuracy. + Offers a potential pathway to integrate sustainability or ergonomic considerations into layout planning thus supporting long-term business goals. Critical View of Value Stream Mapping A holistic approach focused on eliminating waste and optimizing entire process flow Advantages Disadvantages Opportunities + Created efficient cellular + Implementation can be complex, + Can drive innovation by identifying ‘manufacturing arrangements pee aioe additional process improvements + Best simulation results (24% peel oreecentones ey beyond layout. reduction in worker movement, elie nhieces enter + Provides a scalable framework €6,000 additional revenue) Pane mrTiar a ene adaptable to other production lines or + Identifies and removes non-value- delaying ROI. industries, increasing long-term value. added activities like waiting and + Reduced throughput times overproduction. + Potential for continuous improvement Enabled identification of additional initiatives improvement. opportunities + Could incorporate Industry 4.0 beyond layout while optimizing technologies current operations add limitation and opportunity to each iE oe —_— e » + one PROPOSED ENHANCEMENTS Empirical Layout and Value Stream Mapping w@ Empirical Layout for Fur Manufacturing Currently, primarily based on ‘generic guidelines and outdated practices, lacking _direct alignment with practical factory ‘constraints. ENHANCEMENTS ‘Sequential flow with minor adjustments for unique operational needs, Grouping of similar operations such as blowing, basting, and pre- falling + Placement of "dirty" operations (blowing, basting, dying) in proximity for easier waste ‘management. + Co-location of final quality control operations like stiffening and finishing, nale & Key Deliverables 01 + Leverages existing worker experience and factory-specific knowledge. + Efficient for small batches and low- volume operations with constrained Reduces handling time and transportation distance by grouping related processes. 02 Quick implements reliance on existing factory knowledge. Improved material flow with reduced handling and operator travel time. Enhanced waste management through better proximity of “dirty” operations. Moderate improvement in throughput, efficiency, and worker satisfaction. due to VSM for Fur Manufacturing Currently focuses on individual ions without considering flow of materials and information. ENHANCEMENTS + Comprehensive mapping of the entire value stream, from raw ‘material intake (fur) to finished products. Identifying bottlenecks, delays, and non-value-adding activities (eg, excessive waiting times, transportation). Introduction of a dedicated semi- finished product storage area to optimize flow. Grouping of steeping, drying, and dying into acellular ‘manufacturing layout. Rationale & Key Deliverables 01 ‘+ A holistic approach that examines the entire process to identify inefficiencies and waste. ‘+ Focus on kaizen and eliminating non- value-adding activities like waiting times. + Promotes smooth flow of materials and. information, enhancing overall process efficiency. 02 + Clear identification of waste and bottleneck: in the production flow with improved workflow, reducing waiting times etc. + Streamlined process: lowers lead time and maximizes throughput. + Enhanced worker ergonomics & reduced movement time through optimized workstation arrangements. + Potential increase in output and revenue with fewer non-value-adding activities. Proposed Output Efficiency + Current: Efficiency is constrained by individual workstation setups without integration of process flow. ‘+ Proposed: VSM based approach enable better efficiency by optimizing the entire production flow, reducing redundant movements and waste, and enhancing overall system coordination. Productivity + Current: Productivity is often low due to inefficiencies in material flow, long waiting times, and bottlenecks in the production process + Proposed: Both lead to a more streamlined production process with optimized layouts, increasing throughput and fulfling more orders per year, as demonstrated by an increase in productivity. Manpower Management + Current: Workers are often over-utilized or under-utilized, and manual adjustments are frequently needed due to ‘non-optimal workstation layouts. + Proposed: By utilizing lean principles and VSM, manpower can be managed more effectively by grouping related ‘tasks, reducing worker movement, and ensuring better alignment between workstations and labor availabilty ~~ o 4 S é

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