Investigations on performance of process, cellular and virtual cellular layouts

Abstract

In today's competitive world, the market demand is characterised by high variability in volume and product mix. The market demand, which is a major input to layout planning highly influences the performance of production system. This paper presents a simulation-based study to demonstrate the influence of layouts on shop floor performance. A subcontracting industry where process layout in existence is chosen for study and the performance of three different layouts namely process, cellular and virtual cellular layouts are evaluated through WITNESS 2006 simulation software. The operational parameters such as part mix variation, setup time and batch size are used for the study. Design of experiments is used to find out the optimum layout based on the performance indicators namely throughput, average percentage utilisation of machines, average work-in-process (WIP) and average flow time. Finally, the performances of cellular and virtual cellular layouts are compared with process layout.

Facility layout selection guideline under dynamic demand and part variety

“…A significant number of factors, levels and replications were used seeking to delimit appropriately the range in which the virtual cells effectively lead to competitive advantages. Jayachitra and Prasad (2011) [26] used performance indicators namely throughput, average percentage utilization of machines, average WIP and average flow time to compare the performances of cellular and virtual cellular layouts with the existing process layout of a sub contacting industry. Prasad and Aravinthan (2011) [27] studied a pump manufacturing industry and analyzed its existing process layout with that of cellular layout for the production line of two different models of submersible pump.…”