Modified SLP for Layouts in the Production of Small Items Using Small Machinery

Some products are made from many very small off the shelf components. In these cases normally the devices and work stations used for production or assembly are also small. In the existing layout design methodologies, particularly the Systematic Layout Planning, SLP, material flow plays a significant role in the layout design process. In fact most of these methods have been designed to deal with large flow and equipment. This paper discusses the issues and techniques required in layout design in a manufacturing environment for small products using small machinery. It attempts to modify the SLP to cater for these cases by additional checks and calculations. In particular it uses commonality ratio, to identify component commonality between products or facilities, as a basis for development of their relationships. The methodology was applied to redesign the layout of a manufacturing situation. The existing evolved layout has gone to its limits of congested flow, low traceability of products, lack of visibility and disorganisation. Implementation of the new approach resulted in a layout with higher efficiency of space usage, good visibility, and effective material flow, as compared with the current layout