Abstract
In the present competitive market scenarios, the beverage industries are working hard to increase the production volume without compromising the quality of products. There are many ways to improve the effectiveness and performance of the production lines, such as minimizing the transportation time between the locations, utilizing the buffer storages, removing and replacing manually operated and semi-automatic machines, use of group technology and many more methods. In the present study, a beer production company located in Sonipat (Haryana) India is a Small-to-Medium Enterprise (SME) striving to improve its production line layout. Thus, the exiting layout of the production line has been simulated using ProModel© 7.5 simulation software and two alternative production line layouts have been suggested with improved work-in-progress, higher production volume and less transportation time. In one alternative layout, the buffer storage and rearrangement of machines for shortening the travel distance have been introduced and in another alternative layout, the automatic guided vehicle has been replaced with the conveyor as well as two machines namely filling machine and capping machine have been replaced by a machine called Filling and Capping machine in order to perform both operation at the same time. Various conclusions have been drawn and the cost analysis has been presented to justify the suggested changes.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Monroy, D.F.Z., Vallejo, C.C.R.: Production planning and resource scheduling of a brewery with plant simulation. In: Use Cases of Discrete Event Simulation, pp. 321–330. Springer, Berlin, Heidelberg (2012)
Matende, N.R.: Optimization of packaging operations for Beer production line effeciency (Doctoral dissertation, Kyambogo University) (2019)
Savsar, M.: Flexible facility layout by simulation. Comput. Ind. Eng. 20(1), 155–165 (1991)
Drira, A., Pierreval, H., Hajri-Gabouj, S.: Facility layout problems: a survey. Annual Rev. Control 31(2), 255–267 (2007)
Chierotti, M., Rozenblit, J.W.: Simulation modeling in factory layout optimization. IFAC Proc. Vol. 25(28), 235–239 (1992)
Phanden, R.K., Demir, H.I., Gupta, R.D.: Application of genetic algorithm and variable neighborhood search to solve the facility layout planning problem in job shop production system. In: 2018 7th International Conference on Industrial Technology and Management (ICITM), pp. 270–274. IEEE (2018)
Phanden, R.K., Saharan, L.K., Erkoyuncu, J.A.: Simulation based cuckoo search optimization algorithm for flexible job shop scheduling problem. In: Proceedings of the International Conference on Intelligent Science and Technology, pp. 50–55 (2018)
Phanden, R.K., Palková, Z., Sindhwani, R.: A framework for flexible job shop scheduling problem using simulation-based cuckoo search optimization. In: Advances in Industrial and Production Engineering, pp. 247–262. Springer, Singapore (2019)
Sharma, P., Phanden, R.K., Singhal, S.: A comparative analysis of facility layout design and optimization techniques. In: Proceedings of the 2nd National Conference on Advancements in the Era of Multi Disciplinary Systems (AEMDS-2013) (2013)
Sharma, M., Phanden, R.K., Sharma, P.: Comparative evaluation of facility layout alternatives based on material handling cost. Int. J. Technol. Res. Eng. 7(2), 748–751 (2015)
Altinkilinc, M.: Simulation-based layout planning of a production plant. In: Proceedings of the 2004 Winter Simulation Conference, 2004, vol. 2, pp. 1079–1084. IEEE (2004)
Tearwattanarattikal, P., Namphacharoen, S., Chamrasporn, C.: Using ProModel as a simulation tools to assist plant layout design and planning: case study plastic packaging factory. Songklanakarin J. Sci. Technol. 30(1) (2008)
Smutkupt, U., Wimonkasame, S.: Plant layout design with simulation. In: Proceedings of the international multi-conference of engineers and computer scientists, vol. 2, pp. 18–20 (2009)
Jayachitra, R., Prasad, P.S.S.: Design and selection of facility layout using simulation and design of experiments. Indian J. Sci. Technol. 3(4), 437–446 (2010)
Edis, R.S., Kahraman, B., Araz, Ö.U., Özfırat, M.K.: A facility layout problem in a marble factory via simulation. Math. Comput. Appl. 16(1), 97–104 (2011)
Shariatzadeh, N., Sivard, G., Chen, D.: Software evaluation criteria for rapid factory layout planning, design and simulation. Procedia CIRP 3, 299–304 (2012)
John, B., Jenson, J.E.: Analysis and simulation of factory layout using ARENA. Int. J. Sci. Res. Publ. 3(2), 1–8 (2013)
Said, M.A.B.M., Ismail, N.B.: Improvement of production line layout using arena simulation software. In: Applied Mechanics and Materials. vol. 446, pp. 1340–1346. Trans Tech Publications Ltd. (2014)
Kumar, V., Verma, P., Onkar, S.P.S., Katiyar, J.: Facility and process layout analysis of an SME using simulation: a case study of a manufacturing company. In: Conference Paper Presented at: International Conference on Industrial Engineering and Operations Management, pp. 8–10 (2016)
Polshettiwar, A.A., Trivedi, D.P., Sardar, M.V.B., Rajhans, N.R.: Optimization of plant layout using simulation software. In: Conference 6th International and 27th All India Manufacturing Technology, Design and Research Conference (AIMTDR-2016), 16–18 Dec 2016 at College of Engineering, Pune, Maharashtra, India (2016)
Patil, R.J., Kubade, P.R., Kulkarni, H.B.: Optimization of machine shop layout by using flexsim software. In: AIP Conference Proceedings, vol. 2200, no. 1, p. 020033. AIP Publishing LLC, (2019)
Singh, P.L., Sindhwani, R., Dua, N.K., Jamwal, A., Aggarwal, A., Iqbal, A., Gautam, N.: Evaluation of common barriers to the combined lean-green-agile manufacturing system by two-way assessment method. In: Advances in Industrial and Production Engineering, pp. 653–672. Springer, Singapore (2019)
Sindhwani, R., Singh, P.L., Prajapati, D.K., Iqbal, A., Phanden, R.K., Malhotra, V.: Agile system in health care: literature review. In: Advances in Industrial and Production Engineering, pp. 643–652. Springer, Singapore (2019)
Mittal, V.K., Sindhwani, R., Singh, P.L., Kalsariya, V., Salroo, F.: Evaluating significance of green manufacturing enablers using MOORA method for Indian manufacturing sector. In: Proceedings of the International Conference on Modern Research in Aerospace Engineering, pp. 303–314. Springer, Singapore (2018)
Sindhwani, R., Singh, P.L., Iqbal, A., Prajapati, D.K., Mittal, V.K.: Modeling and analysis of factors influencing agility in healthcare organizations: an ISM approach. In: Advances in Industrial and Production Engineering, pp. 683–696. Springer, Singapore, (2019)
Mittal, V.K., Sindhwani, R., Shekhar, H., Singh, P.L.: Fuzzy AHP model for challenges to thermal power plant establishment in India. Int. J. Oper. Res. 34(4), 562–581 (2019)
Sindhwani, R., Singh, P.L., Chopra, R., Sharma, K., Basu, A., Prajapati, D.K., Malhotra, V.: Agility evaluation in the rolling industry: a case study. In: Advances in Industrial and Production Engineering, pp. 753–770. Springer, Singapore (2019)
Sindhwani, R., Mittal, V.K., Singh, P.L., Kalsariya, V., Salroo, F.: Modelling and analysis of energy efficiency drivers by fuzzy ISM and fuzzy MICMAC approach. Int. J. Prod. Quality Manag. 25(2), 225–244 (2018)
Acknowledgements
We are highly thankful for the company management to provide us the complete details of machines and equipment. Also, we are grateful to the managers of the company for their kind support and guidance.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2021 The Editor(s) (if applicable) and The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.
About this paper
Cite this paper
Phanden, R.K., Chhabra, J., Chaudhary, T., Kaliramna, A. (2021). Improvements in Production Line Using ProModel© Simulation Software: A Case Study of Beer Beverage Company in India. In: Phanden, R.K., Mathiyazhagan, K., Kumar, R., Paulo Davim, J. (eds) Advances in Industrial and Production Engineering. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-33-4320-7_2
Download citation
DOI: https://doi.org/10.1007/978-981-33-4320-7_2
Published:
Publisher Name: Springer, Singapore
Print ISBN: 978-981-33-4319-1
Online ISBN: 978-981-33-4320-7
eBook Packages: EngineeringEngineering (R0)