Lean Enterprises and New Manufacturing Technologies

Implementation of Lean Energy

Management in Plant Layout Facility
1 .Plant Layout has a direct impact on material flow.
2. An effective tool in re-engineering activity is the value stream mapping.
References
• Energy Management in a Manufacturing
Industry through Layout Design (2017)
• Re-Engineering Assembly Line with Lean
Techniques (2016)
Key Words
• Lean Manufacturing
• Energy Management
• Plant-Layout
• Value Stream Mapping
Energy Management in a Manufacturing Industry
through Layout Design (Lean Transcends Green)
• Energy management is a step towards green manufacturing and sustainability.
• Energy management is a cyclic process and continuous improvement applied in various
industries by the means of Energy Audit.
• Lean Manufacturing is to increase productivity i.e. minimizing cost and time.
• Green manufacturing is precisely concerned with wastes with affect the environment.
• Kyoto Protocol [United Nations Framework Convention on Climate Change]
• ISO 14001 (Reduce the environmental footprint of a business and to decrease the
pollution and waste a business produces).
• Systematic Layout Planning [Minimum Material Flow] i.e. U-Shaped Layout
• The benefits of energy management
• Economic savings An energy audit is a procedure that
• Reduced emission. evaluated the way energy used in a
factory and identifies alternatives for
reducing energy costs.
Energy Management in a Manufacturing Industry
through Layout Design (Lean Transcends Green)
Re-Engineering Assembly Line with Lean
Techniques
• Process begins from current value stream mapping , and drawing future value stream
mapping to establishing implement plan.
• Re-engineering focuses on some aspects such as reducing wastes, standardizing works,
internal logistics , workplace designing and changing layout.
• The challenge is how to fill the gap between current and the future map.
• Aspects on workspace design, operation standardization, line balancing, material flow,
layout changing, much unnecessary raw material and WIP inventory, and mindset
changing.
• Basic Analysis
• Basic Training
• Workplace Optimization
• Internal Logistic Design
• Cardboard Design
• Layout Design
• Implement and Review
About
• The aim is to improve the plant layout of flour mill industry to eliminate
obstructions in material flow and thus obtain maximum productivity of
employees as well as plant.
• Benefit of improving plant layout
• Minimizes material handling, time and cost.
• Allow flexibility of operations
• Easy production flow
• Economic use of the building
• Effective utilization of manpower
• Safety
• Comfort at Work
• Maximum exposure to natural light and ventilation.
About Industry

• TIRUPATI FLOUR MILL INDUSTRIES is a small scale manufacturing plant of flour

machines.
• It was established in year 1996 and since then, it is working in the field of
manufacturing flour machines in Banmore Industrial Area in Morena District, Madhya
Pradesh.
• It operates its plant in process such as casting, machining, painting, and packaging.
• It is spread in area of 5610 square-feet with well organized structure.
• It has a production of 10 to 15 machines per day, which leads it to a 4500 to 5000
machines per year of different sizes, with its small man power.
• This industry have yearly turnover of nearly 2 crores which are most likely figure of
small scale industry
About Industry

• TIRUPATI FLOUR MILL INDUSTRIES is a small scale manufacturing plant of flour

machines.
• It was established in year 1996 and since then, it is working in the field of
manufacturing flour machines in Banmore Industrial Area in Morena District, Madhya
Pradesh.
• It operates its plant in process such as casting, machining, painting, and packaging.
• It is spread in area of 5610 square-feet with well organized structure.
Material Flow

Hopper
Casting Surface Grinding Machining Drilling Welding Energy Stone
Manufacturing Shop Making Assembly Painting Packaging
Shop
Existing Plant Layout
EVENT Description Symbol Time Distance Method
Recommended
Casting Ο Ỻ → D ∇ 0
To Grinder Ο Ỻ → D ∇ 2 min 10 ft
Surface Grinding Ο Ỻ → D ∇ 10 min
To Drill Ο Ỻ → D ∇ 5 min 85 ft Machine relocating
Machining (Drilling) Ο Ỻ → D ∇ 5 min
To Lathe Ο Ỻ → D ∇ 9 min 75 ft
Machining (Lathe) Ο Ỻ → D ∇ 6 min
WIP Inventory Ο Ỻ → D ∇ 20 ft
Energy Stone M, Ο Ỻ → D ∇
To Lathe Ο Ỻ → D ∇ 60 ft Machine relocating
Machining (Lathe) Ο Ỻ → D ∇
WIP Inventory Ο Ỻ → D ∇ 20 ft
Hopper Shop Ο Ỻ → D ∇
Assembling Ο Ỻ → D ∇ 35 ft
Painting Ο Ỻ → D ∇ 20 ft
Packaging Ο Ỻ → D ∇ 20 ft
Problems in Existing Plant Layout

• Work piece to the machine shop [rough grinded after

casting, heavy dust particles are out from the
operation]
• Welding Shop is located near assembly area and lathe
machines [Welding fumes makes uncomfortable to
work]
• Hydraulic press kept facing an assembly line.
• WIP inventory is kept at right boundary of the plant.
Improvement in Existing Plant Layout

• Welding shop should have exhaust proper space.

• After grinding the raw material have to travel long distance to
reach up to its next stage i.e. lathe. Therefore distance should
be reduced.
• After grinding the raw material have to travel long distance to
reach up to its next stage i.e. lathe. Therefore distance should
be reduced.
• If production will increase. So it is obvious that we need more
space to place our inventory like finish product.
• WIP should be in such position. So, it will be able to reduce
delay in assembly.
List of unwanted motion of the material

• Drum, drum cover are travelling distance of 75 ft. to reach

lathe.
• Drum cover are also travelling distance of 20 to 25 feet
more due to improper arrangement of drill.
• Hoppers are also travelling 20 to 25 feet.
• Emery stone grinder travels approx. 52 feet to have
machined.
• In assembly of machine worker have to travel distance
about 30-40 feet to collect the component like bearing
grease, bearing hose, nuts, bolts, spring etc.
Improved Plant Layout

• Location of driller [By changing the position of driller 2

and 3]
• Providing a lathe near to the emery stone grinder
shop.
• Providing a hand driller near to lathe no. 4
• Changing position of welding shop.
• Position of hydraulic press and grinder.
• Packaging and painting department.
Planned Plant Layout
Result

• Plant layout and facility design is effective tool to the production

engineer to use a plant’s space and the other resources such as man,
machine, and money
Research Presentation