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TABLE OF CONTENTS
Abstract…………………………………………………………..………………...….i Dedication……………...…………………………………………………………….iii
Acknowledgement……………..…………………………………………………….iv Table of Contents ……………………………………………………………..……...v
List of Figures ………………………...………………………………………….....xii List of Tables …………………….………………………………………………...xvi
List of Abbreviations, Symbol and Specialized Nomenclature…………………...xviii List of Appendices …………………………………………………….…………...xix
1. INTRODUCTION 1
1.1. Introduction 1
1.2. Project Background 2
1.3. Problem Statement 3
1.4. Aims and Objective 3
1.5. Scope of Project 4
1.6. Expected Result 4
1.7. Methodology and Flow Chart 5
1.8. Summary 5
2. LITERATURE REVIEW
7 2.1 Introduction of plant layout
7 2.2 The Plant Layout Problem
9 2.2.1 Minor changes in present layouts
10 2.2.2 Existing layout rearrangement
10 2.2.3 Relocating into existing facilities
10 2.2.4
Building a new plant 11
2.3 Objective of layout planning 11
2.4 Traditional Types of Facility Layout 11
2.5 Non-Traditional Types of Facility Layouts 12
vi 2.5.1 Agile Manufacturing Layouts
13 2.5.2 Flexible Plant Layouts
14 2.5.3 Fractal Layout
15 2.5.4 Holonic layout
16 2.5.5 Hybrid Cellular Layouts
16 2.5.6 Modular Layouts
17 2.5.7 Multi-Channel Manufacturing
17 2.5.8 Organization of Factories as Responsibility Networks
18 2.6 Trends in Facility Layouts observed in Industry
19 2.6.1 Reconfigurable Manufacturing Systems RMS
19 2.6.2 Flow Manufacturing – Linked Cells
20 2.7 Systematic Layout Planning With Production Flow Analysis
21 2.8 Tools for design of facility layouts
25 2.9 Company Overview CTRM Aero Composite Sdn Bhd
30 2.9.1 Introduction
30 2.9.2 Process Flow: A320 Phase 1- Leading Edge LE, Tailing
Edge TE, Aileron, Over Wing, Under Wing, A320A321 Affixed Fairing, Movable Fairing
32 2.9.3 Process Flow: A320 ASSY Top Skin False Work
33 2.9.4 Process Flow: A320 Phase 2 Spoiler
34 2.10 Summary
35
3. METHODOLOGY 36
3.1 Introduction 36
3.2 Project Overview 37
3.3 Problem Identification 37
3.4 Data collection 39
3.5 Data Analysis 39
3.5.1 Process Analysis Technique 39
3.5.1.1 Conduct a Preliminary Study 40
3.5.1.2 Draw Up a Process Flow Chart 40
3.5.1.3 Record Measurements for All Required Items 41
vii 3.5.1.4 Draft an Improvement Plan
41 3.5.1.5 Data Comparison between Current Condition and
Improvement Plan Using Pareto Chart. 41
3.5.2 Workplace Analysis 43
3.5.2.1 Illuminance Noise Measurement 43
3.5.2.1.1 Selecting the Workplace 45
3.5.2.1.2 Set Up the Equipment 45
3.5.2.1.3 Collecting Data 45
3.5.2.1.4 Analysis Data 45
3.5.2.1.5 Suggestion and Improvement Plan 45
3.5.2.2 Muscle Fatigue Assessment 46
3.5.2.2.1 Preparing the Questionnaire 46
3.5.2.2.2 Select the workplace 46
3.5.2.2.3 Analysis the questionnaire 47
3.5.2.2.4 Suggestion and Improvement Plan 47
3.6 Proposed the New Layout 49
3.7 Summary 49
4. RESULT AND ANALYSIS 50
