Procedia Engineering 96 ( 2014 ) 355 – 361
1877-7058 © 2014 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/).
Peer-review under responsibility of organizing committee of the Modelling of Mechanical and Mechatronic Systems MMaMS 2014 doi: 10.1016/j.proeng.2014.12.125
ScienceDirect
Modelling of Mechanical and Mechatronic Systems MMaMS 2014
CASE STUDY OF MODELLING THE LOGISTICS CHAIN IN PRODUCTION
Miriam Pekarþíková
a,Peter TrebuĖa
b,Jaromír Markoviþ
c*
a,bTechnical University of Košice, Faculty of Mechanical Engineering, Institute of Technologies and Management, Department of industrial engineering and management, NČmcovej 32, 042 00 Košice, Slovak republic
cDirectorate Banská Bystrica, Hviezdoslavova 31, 97401 Banská Bystrica, Slovenská republika
Abstract
Article deals with the optimization of the production chain, namely the optimization of material flow by reducing the costs of transporting products and semi-products in the production process. Selected method was CRAFT, which can be used to determine the optimal relative position of the various elements in the arrangement of whole.
Keywords: optimization;logistic chain;production;transporting;costs.
1. Introduction and realization
Aim of the case study is to find the best possible layout of in plan view, the best way to organize a whole. Economically attractive solutions is conditional on the higher effect from the optimized layout i.e. the cost of transferring elements in initial layout are higher that the cost related with reorganization. Initial production hall plan view is in Fig. 1.
The distance between productions machines on the factory floor are illustrated in the following figures. To transport materials and semi-products between stock and different production centres used hand pallet truck and pallet truck STILL RX 70 Operating costs and fuel consumption are described in the following Table 1.
Semi-finished product and input material are transferred in crates intended for their temporary storage. Technological process of products can not be changed but can be moved workplaces to optimize the material flow. Fuel consumption of pallet truck STILL RX 70 is estimated at € 0.1 to 100 m. This consumption was calculated on the basis of the maximum achieved trolley speeds - 22 km/h and fuel consumption per norm-hour, which represents 1, 9 l. Based on calculation the distance between the operating centres and the volume of transported semi-finished products and the material is clear, that the most material is transported between the stock and plastic mill. Based on
* Corresponding author. Tel.: +421-55-602-3235; fax: +421-55-602-3234.
data of fuel consumption the pallet truck STILL RX 70, production volume and the distance between the centres can quantify the cost of transporting the material, following Table 2.
Table 1. Basic parameters of a forklift truck
Engine manufacturer - VW
Type of engine - BTX
Engine power according to ISO 1585 kW 28
Rotation 1/min 2350
Number of cylinders - 4
Swept volume cm3 1900
Fuel consumption 1/h, kg/h 1,9*/2,0*
Table 2. Calculation of intensity of material flow
Manufacturing operation Daily norm Distance [m]
Intensity of material flow
warehouse-automatic straightening machine 60444 7 423 108
automatic straightening machine-turning machine 60400 2 120 888
turning machine-extruder 3400 2,5 2 142 000
extruder-riveting machines Dunkes III. 710 11 1 968 120
riveting machines Dunkes III.- assembly machine RuckZuck II.
3400 3 1968 120
warehouse- straightening machine tapes 50444 3,5 176 584
straightening machine tapes- eccentric press LEN 63 50444 2 109 888
eccentric press LEN 63-riveting machines dunkes I. 420 16,5 1 746 360 riveting machines dunkes I.- assembly machine
RuckZuck I. 4620 1,5 1 746 360
straightening machine- eccentric press ebu 50 50444 2,5 126 110
eccentric press EBU 50- riveting machines dunkes II. 420 18,5 1 958 040 riveting machines Dunkes II.- assembly machine
RuckZuck II. 5180 1,5 1 958 040
warehouse- injection molding machine Selex I. 89575+78250 14 2 349 550 warehouse- injection molding machine Selex II. 89575+78250 19,5 3 272 587 warehouse- injection molding machine Selex III. 89575+78250 18 3 020 850 warehouse- injection molding machine Selex IV. 89575+78250 16,5 2 769 112,5
extruder BE40- chopping machine 325 23 1 883 700
injection molding machine I.- chopping machine 293 13 959 868
injection molding machine II.- chopping machine 270 18,5 1 285 740
injection molding machine III.- chopping machine 410 18 1 859 760
injection molding machine IV.- chopping machine 491 15,5 1 917 846
chopping machine- retractor 1900 4 1 915 200
retractor- welding machine 1900 1,5 718 200
welding machine- riveting machines Dunkes DNX 1900 2,5 1 197 000
injection molding machine Selex I.- assembly machine Rolldry I.
462 9 1 047 816
injection molding machine Selex II.- assembly machine
rolldry I. 390 14,5 1 425 060
injection molding machine Selex III.- assembly machine Rolldry II.
473 14 1 668 744
injection molding machine Selex IV.- assembly machine Rolldry II.
262 11,5 759 276
In the following Table 3 are calculated costs of transporting material between individual manufacturing operations based on previous calculations.
Table 3. Calculation of transport costs
Manufacturing operation Intensity of material flow
Transport costs [€]
warehouse-automatic straightening machine 423 108 42,3
automatic straightening machine-turning machine 120 888 12,1
turning machine-extruder 2 142 000 214,2
extruder-riveting machines Dunkes III. 1 968 120 196,8
riveting machines dunkes III.- assembly machine RuckZuck II. 1968 120 196,8
warehouse- straightening machine tapes 176 584 17,7
straightening machine tapes- eccentric press LEN 63 109 888 11,0
eccentric press LEN 63-riveting machines Dunkes I. 1 746 360 174,6
riveting machines Dunkes I.- assembly machine RuckZuck I. 1 746 360 174,6
straightening machine- eccentric press EBU50 126 110 12,6
riveting machines Dunkes II.- assembly machine RuckZuck II. 1 958 040 195,8
warehouse- extruder BE 40 358 360 35,8
warehouse- injection molding machine Selex I. 2 349 550 235,0
warehouse- injection molding machine Selex II. 3 272 587 327,3
warehouse- injection molding machine Selex III. 3 020 850 302,1
warehouse- injection molding machine Selex IV. 2 769 112,5 276,9
extruder BE 40- chopping machine 1 883 700 188,4
injection molding machine I.- chopping machine 959 868 96,0
injection molding machine II.- chopping machine 1 285 740 128,6
injection molding machine III.- chopping machine 1 859 760 186,0
injection molding machine IV.- chopping machine 1 917 846 191,8
chopping machine- retractor 1 915 200 191,5
retractor- welding machine 718 200 71,8
welding machine- riveting machines Dunkes DNX 1 197 000 119,7
injection molding machine Selex I.- assembly machine Rolldry I. 1 047 816 104,8 injection molding machine Selex II.- assembly machine Rolldry I. 1 425 060 142,5 injection molding machine Selex III.- assembly machine Rolldry II. 1 668 744 166,9 injection molding machine Selex IV.- assembly machine Rolldry II. 759 276 75,9
Total 42 852 288 4 285,3
The total cost of transporting material among production centres were 4285,3 €. From the calculations is also possible to determine among which particular production centres was the largest transport costs. This represents the material flow between the stock and plastic mill, which is used for the production of components to the products Topdry and Rolldry. In the context of cost optimization as the most suitable alternative seems to be a variant exchange centres P2 and P3, i.e. metal mill and mill plastic. Relocation single machines would be possible by means of bridge crane, which is located in the production hall, the cost of relocation of one machine moving is average 85 €. Proposal plan view of the production hall after the reorganization is shown in Fig.2.
Quantifying the cost of the relocation of individual machines are specified in the following Table 4. Table 4. Calculation of the costs of transporting by method Craft
Manufacturing operation Intensity of material flow Transport costs [€]
warehouse-automatic straightening machine 785 772 78,58
automatic straightening machine-turning machine 120 888 12,09
turning machine-extruder 2 142 000 214,20
extruder-riveting machines Dunkes III. 715 680 71,57
riveting machines Dunkes III.- assembly machine RuckZuck II.
1 968 120 196,81
warehouse- straightening machine tapes 176 584 17,66
straightening machine tapes- eccentric press LEN 63
109 888 10,99
eccentric press LEN 63-riveting machines Dunkes I.
1 746 360 174,64
riveting machines Dunkes I.- assembly machine RuckZuck I.
1 746 360 174,64
straightening machine- eccentric press ebu 50 123 110 12,61
eccentric press EBU 50- riveting machines dunkes II.
1 958 040 195,80
riveting machines Dunkes II.- assembly machine RuckZuck II.
1 958 040 195,80
warehouse- extruder BE 40 850 962 85,10
warehouse- injection molding machine Selex I. 671 300 67,13
warehouse- injection molding machine Selex II. 1 090 862 109,09 warehouse- injection molding machine Selex III. 1 762 162 176,22
warehouse- injection molding machine Selex IV. 827 900 82,79
extruder BE 40- chopping machine 900 900 90,09
injection molding machine I.- chopping machine 922 950 92,30
injection molding machine II.- chopping machine 714 420 71,44
injection molding machine III.- chopping machine 1 653 120 165,31 injection molding machine IV.- chopping
machine 1 794 114 179,41
chopping machine- retractor 1 915 200 191,52
retractor- welding machine 718 200 71,82
welding machine- riveting machines Dunkes
DNX 1 197 000 119,70
injection molding machine Selex I.- assembly machine Rolldry I.
1 280 664 128,07
injection molding machine Selex II.- assembly machine Rolldry I.
771 120 77,11
injection molding machine Selex III.- assembly machine Rrolldry II.
1 549 548 154,95
injection molding machine Selex IV.- assembly
machine Rolldry II. 759 276 75,93
Total 32 933 540 3 293,35
The total cost of transporting material among production centres after reorganization are 3 293, 25€. From the results of the calculation can be stated that the relocation of individual machines have resulted in saving more than 1,000 € per year.
From the calculations can be also compare by how much costs have fallen between specific production centres where the largest transport costs were, Tab 5.
Table 5. Comparison of costs after application methods Craft
Manufacturing operation Before the change After the change
warehouse-injection molding machine I. 235,0 € 67,13 €
warehouse-injection molding machine II. 327,3 € 109,09 €
warehouse-injection molding machine III. 302,1 € 176,22 €
warehouse-injection molding machine IV. 276,9 € 82,79 €
After transfer machines created space for a precise definition routes of movement forklift for material handling between centres and warehouses.
2. Conclusion
Case study focused on the optimization of the production chain by reducing the cost of transporting the material between various production centres. By using methods Craft in the reorganization of the logistics chain was achieve the purpose of the case study and it was the minimize transport costs in production chain.
This article was created by implementation of the grant project VEGA no. 1/0102/11 Experimental methods and modeling techniques in-house manufacturing and non-manufacturing processes.
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