Rearranging and Optimizing of Butterfly Valve Manufacturing Layout Using Simulation

Abstract

Most layouts are designed for the initial conditions of the business; however, as the company grows it has to adapt to internal and external changes; a redesign is necessary for plant layout. There should be a relationship between output, shop floor area and manufacturing process. This study is based on the analysis of the current layout of the butterfly valve in WEIR BDK Valves, Hubballi. The current layout measurement is noted in the initial stage with the current layout and proposed layout drawings with the help of CAD software, and the time study, arrangement of machines, productivity and material flow of current layout are analyzed. The aim of this project is to purpose a new and efficient layout to reduce travel time, to minimize material flow and to find out the most efficient arrangement of machines in the assembly unit of butterfly valve section. The new proposed layout is analyzed using the ARENA simulation software, and the same is implemented in the company. After implementing, the time study, material flow and arrangement of machines of proposed layout are analyzed. This study also illustrates how simulation technique helps in solving the problems in plant layouts. It also helps to modify the plant layout to improve the productivity and overall efficiency of company. The efficient redesign of plant layout is necessary for operations and management costs.