Abstract
Abstract
This paper describes the application of systematic techniques for factory layout improvements undertaken at Renold Gears Limited (Bradford) who manufacture hydraulic and mechanical variable-speed drives. The company needed to redesign its layout to form JIT (just-in-time) manufacturing cells so that improvements in material flow and reduced lead times could be achieved. In this case study, an overview of the plant layout problem is covered for the particular company. A detailed study of the plant layout is then carried out using production flow analysis (PFA) techniques of group technology, ‘from-to’ (cross charts) and relationship (REL) charts. The PFA matrix, with the constraints included, is solved using King's rank order clustering (ROC) technique, through the use of a spreadsheet. Eight manufacturing cells are identified and manual input is carried out to determine the best machine positions within the particular cells. Results of the new cells are presented and compared with the original layout. The case study has shown that the new layout significantly improves the process flow through the plant, helping to reduce waste in terms of scheduling, lead time inventories and space.