Investigation On Facility Layout Design Based On Manufacturing System Functionality

Facility layout is an important part of manufacturing system design. Facility layout meeting the demands of manufacturing system functionality will become the important trend of modern factory design, and has wide application prospects. This dissertation focuses on the types of facility layout bases on manufacturing system functionality. Through the relationship research of customer needs and manufacturing system functionality, topological structures facility layout are proposed. Simulation and evaluation of facility layout are presented, which will provide theoretical basis and technical support for factory design.The theoretical framework of facility layout in manufacturing system is developed, and research levels of it are established. Based on the relationships among production system, manufacturing system and facilty, the research objects of facility layout in manufacturing system are described. The research contents of facility layout problem are divided into three parts: types of facility layout problem, types of facility layout and location of facility. The transform relationships among static facility layout problem, dynamic facility layout problem and robust facility layout problem are studied. Through comparing the facility layout design with reconfigurable manufacturing system design, facility layout is separated into two research levels: layouts for new factories and for existing ones. Introducing the reconfigurability of facilty, the methodology of facility layout for different research levels is presented. The position of manufacturing system facility layout in the theory of facilty design is established according to research object.The method of facility layout design is proposed based on manufacturing system functionality. According to the relationships among customer need, manufacturing system functionality, structure and facility layout, the problem of manufacturing system design is transformed into the problem of facilty layout design. According to the kinds of manufacturing system functionality, quality, manufacturing cost, and lead time embodied in manufacturing process are studied. With the guidance of axiomatic design, the facility layout design process based on manufacturing system functionality is discussed. The customer needs, function requirements, design parameters, and process variables are analyzed in facility layout based on manufacturing system functionality. Subordination relation between axiomatic design and multi-objective optimization theory is proposed. The research results prove that axiomatic design can guide the facility layout design process and multi-objective optimization theory can evaluate solutions of facility layout.Modeling structure of facility layout is given, which includes physical model, mathematical analysis model and simulation model. Mathematical analysis models of facility layout based on manufacturing system functionality are established. On the basis of classified optimization objectives and constraints, block model of facility layout suited to production line is analysed. On the foundation of mapping relationship between optimization objectives and mathematical analysis models, mathematical analysis models based on manufacturing cost are setup, which consist of material handling cost model, area utilization model, equipment utilization model and working time utilization of labor model. Material handling time model is setup, which is mapping to lead time.Topological structure of facility layout is constructed. Application scope, advantages and disadvantages of types of facility layout are compared with different classification standard. Reference on network topological structures and material flow modes, types of facility layout are predicted, and these types of facility layout are modified with graphical topology properties. The research results show that the types of facility layout in manufacturing system include bus-type, network-type, loop-type, star-type and tree-type.Simulation model of piston 117 production line layout is established and the simulation results are evaluated by entropy method. On the basis of topological structure physical model and mathematical analysis models of facility layout, piston 117 production line with types of facility layout is simulated with deneb/QUEST software. Evaluation index system with two levels based on manufacturing system functionality is proposed. Index weights are calculated by entropy method. The calculation results reveal that loop-type of facility layout is chosen to get the lowest manufacturing cost, semi-circle type of facility layout is chosen to get the shortest lead time, and loop-type of facility layout is chosen to get the best comprehensive effectiveness comparing with other types of layout.