Simulation study and analysis of plant layout in tin container industry

Abstract

The productivity of any manufacturing facility depends on how well various processes involved in the plant are interconnected. Plant layout comprises of various departments and within these departments, there are different processes which are interdependent on each other. Proper design of plant layout combines all different workstations under single frame so as to enhance the productivity. But several small scale industries utilize the same old traditional layout which was framed during their establishment and therefore as they grow eventually over the years, due to change in market trends or to meet increasing customer demand redesigning of plant layout plays vital role. Analysis of existing plant layout helps in identifying loophole areas and explores measures to eliminate bottlenecks present. The main aim of this study is to find out most optimal way of arranging various workstations in the existing facility that will satisfy the present day demand from the customers which substantially increases the production rate. This study has been carried out at a tin container manufacturing industry named as LVT containers situated in Hubballi, Karnataka, INDIA. Analysis was conducted using the ARENA simulation software and the results obtained from simulation experiment were the basis for proposing potential changes in the existing plant layout.