Optimizing Dairy Plant Layout Using CRAFT: Enhancing Space Utilization, Efficiency, and Productivity
DOI:
https://doi.org/10.64229/61r6e066Keywords:
Facility Layout Planning, Productivity, Efficiency, Space Utilization, Graph Theory, Computerized Relative Allocation of Facilities Technique (CRAFT)Abstract
Poor aisle configuration on the production floor results in congestion of men and machines, accidents that may lead to serious injury, and consequently, an overall loss in productivity. There is a need to prevent the incessant wastage of a huge number of resources, revenue, and production time as a result of the serial production shutdown, congestion on the floor, and poor space utilization. This research aims to improve the plant layout of a dairy company to ensure optimum space utilization, eliminate obstructions in material flow, and thus obtain maximum efficiency and productivity. Data such as the present layout of the production plant was obtained from the design section of the company Flow process chart of the production process was studied and analyzed using facility layout design concepts, and the proposed layout was developed using the Computerized Relative Allocation of Facilities Technique (CRAFT).
On the proposed layout, a free space of 1620m2 which has the capacity for 997 jumbos, with a layout efficiency of 91%. Comparing the layouts, the proposed layout gives a better space utilization of 50.95% increase in storage capacity (from 489 jumbos to 997 jumbos), and the distance travelled was reduced from 457.24m to 172.20m. which is 62.36%, production time by 7.8% and the material handling cost by 6.2%. This improved space utilization gives room for future expansion and more space for a temporary storage point.
References
[1]Ali Naqvi SA, Fahad M, Atir M, Zubair M, Shehzad MM. Productivity improvement of a manufacturing facility using systematic layout planning. Xu W, editor. Cogent Engineering. 2016 Jul 15;3(1).DOI:10.1080/23311916.2016.1207296
[2]Huang C, Wong CK. Discretized Cell Modeling for Optimal Facility Layout Plans of Unequal and Irregular Facilities. Journal of Construction Engineering and Management. 2017 Jan;143(1):04016082.DOI:10.1061/(ASCE)CO.1943-7862.0001206
[3]Yun L, Wang X, Fan H, Li X. Reliable facility location design with round-trip transportation under imperfect information. Part I: A discrete model. Transportation Research Part E: Logistics and Transportation Review. 2020 Jan;133:101825.https://doi.org/10.1016/j.tre.2019.101825
[4]Chan H, Aris Filos-Ratsikas, Li B, Li M, Wang C. Mechanism Design for Facility Location Problems: A Survey. arXiv (Cornell University). 2021 Aug 1; https://doi.org/ 10.48550/arXiv.2106.03457
[5]Pérez-Gosende P, Mula J, Díaz-Madroñero M. Facility layout planning. An extended literature review. International Journal of Production Research. 2021 Mar 17;59(12):3777-816.V10.1080/00207543.2021.1897176
[6]Jeemit Pate et.al. Study on Various Plant Layouts used in Flexible Manufacturing System. REST Journal on Emerging Trends in Modelling and Manufacturing. 2020 Jun 1;6(2). https://doi.org/10.46632/6/2/5.
[7]Jin H, Zhang M, Yuan Y. Analytic Network Process-Based Multi-Criteria Decision Approach and Sensitivity Analysis for Temporary Facility Layout Planning in Construction Projects. Applied Sciences. 2018 Dec 3;8(12):2434. https://doi.org/10.3390/app8122434
[8]Tshifhiwa Nenzhelele, John Alfred Trimble, Jan Adriaan Swanepoel, Mukondeleli Grace Kanakana-Katumba. MCDM Model for Evaluating and Selecting the Optimal Facility Layout Design: A Case Study on Railcar Manufacturing. Processes. 2023 Mar 14;11(3):869-9. https://doi.org/10.3390/pr11030869.
[9]Lin Q, Wang D. Facility Layout Planning with SHELL and Fuzzy AHP Method Based on Human Reliability for Operating Theatre. Journal of Healthcare Engineering [Internet]. 2019 Jan 14;2019:1-12. Available from: https://downloads.hindawi.com/journals/jhe/ 2019/8563528.pdf.
[10]Zhu T, Balakrishnan J, Chun Hung Cheng. Recent advances in dynamic facility layout research. INFOR/INFOR Information systems and operational research. 2017 Sep 8;56(4):428-56. https://doi.org/10.1080/03155986.2017.1363591
[11]Borthakur A, Nath DrT. An Application of SLP Approach in a Plywood Manufacturing Company for the Selection of an Optimal Plant Layout. International Journal of Industrial Engineering and Design. 2018; https://doi.org/10.37628/ijied.v4i1.542.
[12]Pérez-Gosende P, Mula J, Díaz-Madroñero M. A bottom-up multi-objective optimisation approach to dynamic facility layout planning. International Journal of Production Research. 2023 Jan 24;1-18. ,https://doi.org/10.1080/00207543.2023.2168308
[13]Peron M, Fragapane G, Sgarbossa F, Kay M. Digital Facility Layout Planning. Sustainability. 2020 Apr 20;12(8):3349. https://doi.org/10.3390/su12083349
[14]Yogaswara Y, Dimiyati TT, Asri RR. Grouping Matching using Genetic Algorithm for Dynamic Cell Layout Design. Journal of Modern Manufacturing Systems and Technology. 2022 Mar 31;6(1):1-8. https://doi.org/10.15282/jmmst.v6i1.6893.
[15]Kaosar Ahamed M, Babu A, Babu S, Hossain B, Thakar CM. Layout map in facility layout planning: A fuzzy methodology. Materials Today: Proceedings. 2021 Jun; https://doi.org/10.1016/j.matpr.2021.06.091
[16]Wei X, Yuan S, Ye Y. Optimizing facility layout planning for reconfigurable manufacturing systems based on chaos genetic algorithm. Production & Manufacturing Research. 2019 Jan 1;7(1):109-24. https://doi.org/10.1080/21693277.2019.1602486
[17]Golowich N, Narasimhan H, Parkes DC. Deep Learning for Multi-Facility Location Mechanism Design. 2018 Jul 1; https://doi.org/10.24963/ijcai.2018/36.
[18]Bhattacharya S, Florentin Smarandache, M. Khoshnevisan. MASS-Modified Assignment Algorithm in Facilities Layout Planning. Infinite Study;
[19]Tampubolon, J., Agoestine-Simangunsong, L.D., Agustina Sibuea, M.D. Sembiring, A.C., and Mardhatillah, A. Prayer paper production facility layout redesign using systematic layout planning method and CRAFT. International Journal of Science, Technology & Management. 2020 Nov 30;1(4):448-56. https://doi.org/10.46729/ijstm.v1i4.84
[20]Wright, G. A Report on C.R.A.F.T.-Computerized Relative Allocation of Facilities Technique. 1973.
[21]King EW. Extension and Application of Craft. 1969.
Downloads
Published
Issue
Section
License
Copyright (c) 2025 Michael Kolawole Oluwanimifise, Christopher Osita Anyaeche (Author)
This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.
