Logistics and simulation of a fabrication and warehousing facility

Abstract

This study examines the fabrication and warehousing facility at Vassallo Group with the aim of reaching optimal efficiency by maximising workflow and eliminating wasted resources. In this study, the DMAIC methodology was selected for both factory level and process level as it was deemed systematic and logical. Regarding factory level, the priority was to minimise travel times between departments and also from the departments to outside the facility. The data was gathered through time and quantity studies. The main focus here was on the store as the movement of goods concerns this department. The purpose of the time study was to analyse the length of time needed by the storekeeper to travel from his/her office to the refuelling station; the quantity study involved an analysis of the transactions. When divided into external and internal transactions, it resulted that the majority of transactions were external. The creation of an As-Is 3D CAD model was followed by a To-Be 3D CAD model based on data analysed in the As-Is model. The travel data for refuelling was then calculated for both the As-Is and To-Be models and it was found that the time saved was fifty-three seconds per trip. Once this was concluded, the joinery was chosen to be looked at in greater depth since this department was identified as having potential for alterations to occur within it. The joinery was the focus point for process level improvement so as to optimise the production and reduce travel time between processes. The data was collected through time studies where all the travel time values were collected. Once these were collected, an As-Is 3D CAD model and a simulation were created for the existing process. After this, a To-Be 3D CAD model of the proposed process layout was generated. This incorporated the proposed alterations which aimed at eliminating bottlenecks and wasted resources. A simulation model was then generated with the new timings, and this was compared to the As-Is simulation to find out the difference in time between the As-Is and the To-Be models. From this, it was concluded that when handling a product with a high assembly time, assigning an additional person to this stage of production would reduce assembly time significantly. The factory level and the process level were then combined into one whole system through 3D CAD modelling and an overall proposed improved model of the fabrication and warehousing facility at Vassallo Group was produced.