This confirms that the thesis titled "Optimal Store Layout Planning and Warehouse Spare Parts Allocation" was completed by Mosammat Ferdaushi Sultana at the Department of Industrial Engineering and Management. Thus, in this research, a standard model for the distribution of spare parts in the store is developed. Theoretically, the plant uses a sequential system when allocating all spare parts to storage shelves, i.e.
Nomenclature
General
If the parts are located in a random order, the storekeeper will have problems in issuing the goods. Again, if the parts are kept in a fixed place, it will be difficult for storekeeper to find out the desired items quickly. If these steps can be taken simultaneously, the warehouse will be able to manage the parts quickly and effectively.
Introduction of the Barge Mounted Power Plant
To avoid these difficulties, spare parts should initially be arranged so that both retrieval/storage time and handling costs are minimized. Sometimes spare parts can be arranged in ascending order of the inventory unit, or slow-moving and fast-moving items can be taken into account. If the spare parts are in large numbers, it is very important to find out the location of the spare parts very quickly. This saves both pick-up/release time and material handling costs.
Existing system of store allocation and assignment of spare parts
Drawbacks of present store allocation system
Objective
Existing classification of spare parts
Store Location and Layout Considerations
The total area of the building and the area of individual departments in the floor plan Arrangement of equipment in the plant [13].
Material Handling and Storage Systems
Spare Parts
The 20% percent of SKUs that account for 20% percent of annual dollar spend fall into this group. Class C Items: The Largest Groups 70% of the SKUs that account for 10% percent of annual dollar spend fall into this group [4]. In an organization that sells spare parts, unavailability will result in loss of company image.
Development of Storing system
Therefore, careful analysis of all phases of the sequence assembly operation is essential for a sequence location system to be implemented effectively. If a small percentage of items are in high demand, the overrun will greatly increase assembly time. Additionally, where conventional shelving is used, the center position of the unit is used for small popular items, the top shelves for lightweight and less popular items, and the bottom shelves for heavy items.
Warehouse management system (WMS)
- Inventory Management System
- Codify and Identify
Codes for parts and equipment manufactured by the supplier other than Wartsila are as follows: The first letters of each word identify the name of the manufacturer when the name has two or more words. If the name of the manufacturer has only one word, the first three letters are used. Scheduled and actual time/date of start and completion of the work and machine shutdown.
Material handling analysis and techniques
The product of these two parameters gives a measure of what Muther and Hagans call transport work, TW, where TW = RfLd Pcs-ft/year [13]. These different deliveries can be combined to determine the total transport work, TTW = RfLd Pcs-ft/year [13]. The successful and cost-effective operation of a power plant is closely related to high quality maintenance.
MAMA Pro takes care of all areas of management, maintenance and management of the warehouse for the entire installation and meets the requirements for full control of all activities, a systematic way of working and good follow-up procedures. This is a computerized maintenance management system software application invented by Datastream System Inc., 50 Datastream Plaza, Greenville, SC 29605. The Mama software stores all WMS information in a database, a collection of related information stored in tables.
Equipment data is in one table, inventory data is in a second table, and work order data is in a third table. Mama software tracks inventory items including usage, quantities at multiple locations and sites, replacement items, vendors and reorder points. Whoever has access to the database at any time can add, change or delete information in any record in the table.
Group technology
The parts in a family are different, but their similarities are close enough to merit their identification as members of the part family. Therefore, the processing of each member of a given family would be similar and this results in production efficiency. Part classification and coding is about identifying similarities between parts and relating these similarities to a coding system.
While the processing steps required to produce a part are usually closely related to the design attributes of the part, this is not always the case. Accordingly, classification and coding systems are often designed to allow for differences between the design of a work and its production [1 fl. The spare parts that we need for a particular maintenance are similar every time, so if we arranged all the spare parts on the shelves according to the similarity of use, the issuing/retrieving of the spare parts will be easier and less time-consuming.
In this chapter, some concepts used in this research and the proposed algorithm for warehouse layout planning are provided.
Family of Spare parts
It is equal to the total number of items issued/used in each SPF per year or the total frequency of use of all items of a given SPF. Therefore, the weight of an SPF is the sum of the usage frequency of all items in a year. An example is given below for the weight calculation for SPF 471, which contains two spare parts, namely a lubricating oil insert (LO) and a seal set only.
Distance calculation
Proposed algorithm
The factory's strategy is to keep all spare parts on the warehouse shelves, in ascending order of stock unit, during the receipt of a shipment of spare parts, with the exception of the LO and FO filter. It is observed that the plant more or less follows the "random location and order system". But practically speaking, the demand for spare parts in the past shows that the spare parts required for planned or unplanned maintenance are the same every time.
So all similar items, which we called a Spare Parts Family (SPF), are not located in the same zone or shelf. For this reason, when a request comes in, we have to find spare parts from different zones or shelves. As a result, it takes more time to acquire/stock spare parts and increases material handling costs. So, if proper storage/retrieval methods can be developed, the above mentioned problems can be overcome.
So our goal is to identify the spare part family (SPF) and to calculate the weight of each spare part family (SPF) based on past demand. Thus, if we keep a spare part family (SPF) required by the work order on the same shelf in the warehouse, the delivery/retrieval of spare parts will be easier and less time consuming, and considering the weight, higher weight SPF (fast moving) should be kept near the counter and less weight (slow) SPF should be placed far from the counter. The algorithm proposed in the previous section (3.4) is applied to the warehouse management system of the factory.
Identifying family of spare parts( SPF)
In step 1 of the proposed algorithm (3.4), the weight calculation is carried out according to the procedure described in article # 3.2 of the 56 spare parts family (SPF) for 4000 ((approximately) spare parts used by the maintenance department.
Calculation of distance
Assignment of each spare parts family to shelves
Comparison of existing layout system with the proposed
Sl Code Description Rr,W Ld, TTW for Propo Ld, TTW for No. e # eight Proposed existing sed mean. e e in the average system, the proposed rack system,. Sl Code Description Rf,W Ld, TTW for Propo Ld, TTW for No. e # eight Proposed existing sed mean. e e in the average system, the proposed rack system,. Sl Code Description R1,W Ld, TTW for Propo Ld, TTW for No. e # eight Proposed existing sed mean. e e in the average system, the proposed rack system,.
It is noted that for the existing system for 56 engine parts SPF's total transport work is feet and the total distance traveled is 9,746.43 feet in the year 2007, but for the proposed allocation system the total transport work is only feet and the total travel distance is 4,015, 70 feet in the year 2007, which reduces the transport work to feet and the travel distance to half. So we can say that if we implement this new system, it will be reduced by 76% less work per year compared to the current system. If the facility follows this allocation system, it will save feet less transportation work ten years from now.
Discussion
So the existing system takes a lot of time to issue and retrieve the list of items per work order. The weight of an SPF is the sum of the frequency of use of all items in a year. Taking weight into account, a higher weight SPF (fast moving) should be kept close to the dispensing counter and a lower weight SPF (slow moving) should be placed far from the counter.
Comparing the total transport work and travel distance with 2007 data, it was found that for the existing system for 56 SPF engine parts, the total transport work of feet and total travel distance in 2007 was 9746.43 feet, but for the proposed allocation system, the total transport work of the work is only feet, and the total travel distance is 4015.70 feet in 2007, which cuts the transportation footwork and travel distance in half. So we can say that if we implement this new system, the transportation work will be reduced by 76% and the travel distance by 50%. % compared to the current system. In this research work, the identification of the family of spare parts, the calculation of the distance of each family of spare parts, the calculation of the weight of each family or elements of the spare parts, the arrangement of the family of spare parts on the shelves, and the comparison of the total transport work for each family of spare parts are done manually. . Based on weight, the heavier weight family of spare parts should be kept close to the dispensing counter and the lighter weight family of spare parts should be placed far away from the counter.
A plant can follow a size system, smaller objects in front and largest in the back. Through FSN analysis, unwanted materials and parts can be eliminated from the device, resulting in inventory reduction. PE, Leland Blank, Statistical Procedures for Engineering, Management and Science, McGrow-Hill International Book Company, New Delhi.
Groover Automatisering, productiesystemen en computer Integrated Manufacturing, Prentice, Hall of India private Limited, New Delhi-i.
