Desigining an Integrated Product and Process Layout Using a Simulation: The Case of Plastic Bag Company

This paper proposed an integrated product and process layout for optimizing process plant layout
using a simulation approach. The proposed layout was compared to the existing layout in terms of the average
work-in-process and the average waiting time of work-in-process. Currently, the plastic bag company uses
process layout for its production facility layout and the activity of material movement is conducted in a batch
fashion. In the proposed layout, product layout was utilized for two of six processes and process layout was
utilized for the rest. Product layout changed material movement from batch into one piece flow with material
handling conveyor. Software ProModel 7.0 was run in 1 year run-time with 10 replications. The simulation
results show that the proposed layout reduces the average work-in-process and work-in-process waiting time
in warehouse inspection by 97.92% and 96.82%, respectively. The proposed layout eliminates 47.42 minutes
of the average waiting time in welding cutting temporary storage area.