This presentation discusses a project to improve the manufacturing layout and efficiency of a sheet metal industry. It provides background on sheet metal manufacturing processes and applications. The current manufacturing layout is modeled in ARENA simulation software. The project aims to develop an improved layout using 5S lean manufacturing concepts and model it in ARENA to compare efficiencies. Visual work instructions for the layouts will be created using VKS software. Preliminary results show the improved layout increases production by over 30% with reduced wait times. The project provides learning around the importance of layout optimization and lean manufacturing principles.

1. PRESENTATION TITLEEGME 483 - Computer Integrated Manufacturing
Project
Manufacturing Layout of Sheet Metal
Industry
Group Members
Vivek Menon
Jaishil Patel
Mayur Narkhede
Aakash Patil
Shubham Birar
Kartik Devatwal
Date: 5/11/2018
http://mechanicae-eng.tumblr.com/page/2

2. Introduction
Sheet Metal Industry
• Sheet Metal is a vast Industry
• Sheet metal manufacturing is an industrial process
that strongly depends on numerous interactive
variables like the process layouts and process
parameters
2

3. Sheet Metal Industry
Process Involved :
• Bending
• Roll Forming
• Spinning
• Deep Drawing
• Stretch Forming
• Punching
• Cutting
3

4. Sheet Metal Industry
Applications
• Aerospace Industry
• Medical
• Automobile
• Construction
• Oil and Gas
4

5. Tin/Can Manufacturing
5
• Cans for food and drinks
may be constructed out of
either two or three pieces
of metal
• Two-piece cans are made
from a disc of metal which
is reformed into a cylinder
with an integral end
• Lids for cans are called "can
ends" or simply "ends"

6. Project Goal
• To increase the manufacturing efficiency by modifying the
current layout
• Efficiency is calculated by comparing the current and newly
drafted layout
• New layout is drafted using 5S lean manufacturing concepts
• The increase in efficiency is simulated on ARENA
• AS 9100 work procedure are drafted using VKS
6

7. Methodology
• “ARENA is a virtual system that communicates with actual
devices”
• In this project ARENA will be used to create Realtime
modelling, System testing and reduce delay in delivery time
• VKS is used for visual work instruction
7

8. 8
Existing Layout
8
Office
Punching
Station
Laser
Machine
Drawing
machine
Printing
Station
Q.C.
Bending
machine
(1) (2)
(3)
(4)
(5) (6)(7)
(8)
(9)
(10)
15
10
11
5
7
5
5
7
Entrance/Exit
Assembly
Station
Final
product
storage
Raw
Material
Storage

9. ARENA Model of Existing Layout
9

10. Improved Layout
10

11. ARENA Model of Improved Layout
11

12. Role of VKS Guidebook
• Visual Work Instructions are made of different
types of multimedia such as images, descriptive
videos, PDFs, and much more
• Paperless work instructions can be viewed on your
tablet or computer and even print them
12Reference: https://www.youtube.com/channel/UCRAxqx4Q1VSxCmSFBL6UTlQ

13. VKS Work Instruction Contd. .
13

14. VKS Work Instruction
14
• Work-Instructions of the workstation were drafted using VKS
Guidebook

15. 15
Parameter Existing Layout Improved Layout
Number of
Products
3837 5757
Old Model Improved Model
Part A Part B Part A Part B
Total Time (Sec) 51 15 18.49 18.5
Wait time (Sec) 5 0 1.99 2.0
No. of Products
Time (sec)
Results

16. Conclusions
• ARENA played a key role for process development
• Learning Outcomes:
– Importance of layout and the component flow in a
manufacturing plant
– Better understanding of 5S Lean Manufacturing was achieved
by implementing it in a realistic industrial example.
• Industrial Outcomes:
– The results of the project can increase the manufacturing
efficiency by at least 30% - 50%
– The results would signify the increase in the manufacturing
capability
16

17. 17

18. 18
Any Questions?