Factory planning and design based on SLP

introduction

In the past 42 years, my country's home appliance industry has experienced a development process from small to large, from weak to strong. However, in recent years, with the gradual saturation of the market and the continuous increase in domestic labor, land and environmental protection costs, many enterprises have encountered bottlenecks in their development. Enterprises urgently need to improve their management level and gradually transform from rough to lean development. Among them, reasonable factory layout is the basis for enterprises to achieve lean production and is of great significance.

Industrial engineering technology has developed rapidly since it was introduced into my country in the 1990s. It has been widely used in recent years and has achieved remarkable results. The author combines traditional design experience with industrial engineering methods to provide a more scientific and systematic solution for factory planning.

1 Introduction to System Layout Design (SLP)

Industrial engineering covers a wide range. This paper adopts the system layout design method (SyStem Layout Planning, SLP) in industrial engineering to carry out the plane layout design of home appliance factory.

The system layout design method (SLP) takes product P, output O, process R, auxiliary service department S and production schedule T as given basic elements (original data) and as the basic starting point for layout design work.

The system layout design (SLP) process is shown in Figure 1.

2 Case study of process layout optimization based on SLP

In view of the unreasonable process layout and chaotic logistics of a certain oil heater assembly workshop, the SLP method was used to optimize its layout. The current process layout is shown in Figure 2.

2.1 Determine the functional area code

The various work units in the oil heater assembly workshop are divided in detail, and the codes of each functional area are shown in Table 1.

2.2 Determine the logistics distance and intensity

According to the production organization form of the oil heater assembly workshop, a statistical analysis was conducted on the logistics routes, distribution methods, etc., and the transportation routes and volumes were obtained as shown in Table 2.

2.3 Draw a From-To Table

The From-To table is also called the flow matrix, which is usually used to represent the flow relationship between production areas. The distance, transportation volume, and logistics intensity of the oil heater assembly workshop are shown in Table 3. From the data in Table 3, it can be seen that the total transportation distance is 2508m, the total transportation volume is 520 pallets, and the total logistics intensity is 87566 pallets m.

2.4 Correlation analysis of functional areas

2.4.1 Logistics relationship analysis

After calculating the logistics intensity, a logistics correlation diagram is established. When establishing the logistics correlation diagram, the logistics intensity needs to be graded to determine the closeness of the relationship between the operating units. The logistics intensity level is often divided into five levels: A, E, I, 0, and U. A accounts for 10% of the total operating units, E accounts for 20%, I accounts for 30%, and 0 accounts for 40%. U represents operating units with no logistics volume between each other. The logistics relationship correlation diagram of each region is shown in Figure 3 (a).

2.4.2 Analysis of non-logistics relationships

After analyzing the logistics relationship between operating units, it is also necessary to analyze the non-logistics relationship between them. Non-logistics relationships are often not quantifiable, and can only be obtained through qualitative analysis to determine the closeness level between operating units. Generally, the closeness level between operating units is divided into 6 levels: A, E, I, 0, U, and x, which represent absolutely important, particularly important, important, general, unimportant, and do not get close. The non-logistics relationship correlation diagram of each region is shown in Figure 3(b).

2.4.3 Comprehensive relationship analysis

In production activities, non-logistics activities are far less important than logistics activities. Therefore, the importance ratio of logistics relationship to non-logistics relationship selected in this paper is 4:1, and the formula for calculating the comprehensive correlation Cij is:

The comprehensive correlation diagram obtained based on the comprehensive correlation is shown in Figure 3(c).

2.5 Arealess Patchwork

Make a block of the same size for each work unit, which is called a non-area block. Write the work code in the center of the block, and place the work unit codes with A, E, I, O, and U relationships in the four corners, respectively. The U-level relationship can be ignored. Taking the oil heater assembly area E as an example, its non-area block diagram is shown in Figure 4. According to this plan, the non-area block diagram of the entire workshop is drawn, and the area is assigned according to the production capacity requirements to obtain the preliminary improvement plan schematic diagram of the oil heater assembly workshop, as shown in Figure 5.

Since Area F is currently a temporary storage warehouse for steel coils and cannot be moved away, a new steel platform is considered as a temporary storage area for packaging materials. The layout diagram of the improvement plan for the oil heater assembly workshop is shown in Figure 6. After calculation, the logistics intensity of the improvement plan is reduced from 87566 pallets·2 to 15789 pallets·2, a decrease of 81m97.: The total transportation distance is shortened from 25082 to 5442, a decrease of 78.31.

3 Conclusion

In summary, the use of industrial engineering methods for factory planning can standardize the design process and provide a rich theoretical basis for the design of home appliance factories. In this paper, the author adopts the system layout design method (SLP) to improve the previous process layout method that mainly relies on experience and qualitative discussion by calculating data, evaluating grades, and combining qualitative and quantitative analysis, and has achieved good results. However, due to the complexity of the process flow of home appliance factories and the variety of actual situations, detailed and detailed data is still needed as a reference, combined with rich practical experience, in order to develop a more complete factory planning plan.