iv OPTIMIZING PRODUCTION LINE OF IBS BY USING SIMULATION MODEL ALI MOHAMMED ALASHWAL A project report submitted in partial fulfillment of the requirements for the award of the Degree of Master of Science (Construction Management) Faculty of Civil Engineering Universiti Teknologi Malaysia November 2006
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iv
OPTIMIZING PRODUCTION LINE OF IBS BY USING
SIMULATION MODEL
ALI MOHAMMED ALASHWAL
A project report submitted in partial fulfillment of the
requirements for the award of the Degree of
Master of Science (Construction Management)
Faculty of Civil Engineering
Universiti Teknologi Malaysia
November 2006
UNIVERSITI TEKNOLOGI MALAYSIA
BORANG PENGESAHAN STATUS TESIS
JUDUL: OPTIMIZING PRODUCTION LINE OF (IBS) BY USING SIMULATION MODEL.
SESI PENGAJIAN: 2005/2006
Saya: ALI MOHAMMED MOHAMMED ALASHWAL.
(HURUF BESAR)
Mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah)* ini disimpan di perpustakaan Universiti Teknologi Malaysia dengan syarat-syarat kegunaan seperti berikut:-
1. Tesis adalah hakmilik Universiti Teknologi Malaysia. 2. Perpustakaan Universiti Teknologi Malaysia dibenarkan membuat salinan untuk tujuan pengajian
sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian
tinggi.4. **Sila tandakan ( )
SULIT (Mengandungi maklumat berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972)
TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan dimana penyelidikan dijalankan
TIDAK TERHAD
Disahkan oleh
(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)
ALAMAT TETAP: PROF. MADYA DR. ABDUL KADIR Yahsob School St. – Yareem – Ibb –
Republic of Yemen. (Phone +9674501550). MARSONO
NAMA PENYELIA
TARIKH:
NOVEMBER 2006
TARIKH:
NOVEMBER 2006
CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa /organisasi erkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM).
Status Declaration Letter
Date: November, 2006
LibrarianPerpustakaan Sultanah Zanariah UTM, Skudai Johor
Sir,
CLASSIFICATION OF THESIS AS RESTRICTED
OPTIMIZING PRODUCTION LINE OF IBS BY USING SIMULATION MODEL
ALI MOHAMMED ALASHWAL
Please be informed that the above mentioned thesis entitled “OPTIMIZING PRODUCTION LINE OF IBS BY USING SIMULATION MODEL” be classified as RESTRICTED for a period of three (3) years from the date of this letter. The reasons for this classification are
(i) COMMERCIALIZATION OF RESEARCH PRODUCT (ii) NEGOTIATION STAGE WITH UTSB SDN. BHD. AS BUSINESS
CONSULTANT (iii) NICHE IBS PRODUCT COMPONENTS ARE WAITING TO BE
MANUFACTURED
Thank you.
Sincerely yours,
ASSOC. PROF. DR. ABDUL KADIR MARSONO M46-23807-5531606013-7257737
iii
“We hereby declare that I have read this project and in my opinion this project is
sufficient in terms of scope and quality for the award of the degree of Master of Science
(Construction Management) by taught course.”
Signature : …………………………………….
Name of Supervisor I : ASSOC. PROF. DR. ABDUL KADIR
MARSONO
Date : November 2006
Signature : ……………………………………
Name of Supervisor II : ASSOC. PROF. DR. MASINE MD. TAP
Date : November 2006
Signature : ………………………………………..
Name of Supervisor II : ASSOC. PROF. DR. AHMAD MAHIR
MAKHTAR
Date : November 2006
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“I declared that this project report entitled “OPTIMIZING PRODUCTION LINE OF IBS
BY USING SIMULATION MODEL” is the result of my own research except as cited in
references. This report has not been accepted for any degree and is not concurrently
submitted in candidature of any degree”.
Signature : …………………………………… Name : ALI MOHAMMED ALASHWAL
Date : November 2006
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Especially dedicated to my beloved family
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ACKNOWLEDGEMENT
The author wishes to express his sincere appreciation to all who have helped
directly or indirectly in his Masters Project research work. The first gratitude is to Allah
for his prosperity and guidance. A big thank is to the project supervisor, Associate
Professor Dr. Abdul Kadir Bin Marsono, for his passionate assistance, and concern. With
his invaluable advices and superb directions, the author has successfully completed his
Masters Project. It is indeed a true honor and privilege for being able to work under the
supervision of such a dedicated and enthusiastic lecturer.
Special thanks are due to Associate Professor Dr. Masine Md Tap for her close
guidance and assistance throughout the process of carrying out the research work.
Besides, the author would like to thank Associate Professor Dr. Ahmad Mahir Makhtar
for his helpful and concern. A particular grateful is due to my cousin Hani Tahir
Alashwal for his unlimited helpful, support, and assistance.
Last but not least, the author would like to express his heartfelt gratitude to his
family members and friends for their utmost support and motivation throughout this
research work. My thanks to them all.
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ABSTRACT
Even though IBS has the ability to offer intensive production elements, the rapid
increasing demands of providing a shelter for every citizen is enforced enhancing the
productivity and the delivery time of IBS. That may obtained by improving the
production line layout of the manufacture plant, enhancing production time, and
resources utilization. Recently, simulation has begun to be applied in construction
industry sector. In this study, “Witness 2001” program has been testified to be able to
build a simulation model for the production line of pre-cast concrete columns and beams.
This simulation model offers the alternatives to modify the production line attributes as
the capacity of elements treatment area, number of re-useable moulds and labour,
breakdown of activities and so on. In fact, that imitates a real plant production line. The
model provides the opportunity to identify the optimum production line of the suggested
layout. This research presents the results of two simulation models either for columns and
beams. The results involve basically on the selection of the appropriate production layout,
the required time to produce the assumed amount of columns and beams. Finally, the
effect of machineries breakdown and the required resources has been determined in this
research.
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ABSTRAK
Walaupun IBS berupaya menawarkan elemen-elemen yang dihasilkan secara
intensif, namun peningkatan terhadap permintaan yang begitu mendadak untuk
menyediakan tempat perlindungan bagi setiap penduduk memerlukan peningkatan
produktiviti dan masa yang lebih singkat. Ianya boleh dicapai dengan memperbaiki susun
atur loji pengeluar bahagian pengeluaran, mengurangkan masa pengeluaran, dan
penggunaan sumber-sumber secara efisyen. Simulasi project ini diuji untuk dalam sektor
industri pembinaan. Dengan pevisian “Witness 2001”, ujikaji bagi menunjukkan
keupayaannya dalam membina model simulasi yang digunakan oleh bahagian
pengeluaran rasuk dan tiang konkrit IBS. Model simulasi yang dimanipulasikan
menawarkan alternatif untuk mengubahsuai ciri-ciri bahagian pengeluaran seperti
kapasiti kawasan yang diperlukan untuk pengawalan pengeluaran, bilangan pekerja dan
bahan yang perlu digunakan, pecahan aktiviti-aktiviti dan sebagainya. Hakikatnya, ianya
menggambarkan keadaan sebenar sesuatu bahagian pengeluaran kilang IBS Sebenarnya,
model yang dihasilkan memberikan peluang untuk mengenalpasti penggunaan susun atur
yang optimum dalam bahagian pengeluaran bagi susun atur yang dicadangkan. Kajian ini
memberikan hasil simulasi dua model iaitu bagi penghasilan tiang dan rasuk. Hasil kajian
secara asasnya melibatkan pemilihan susun atur pengeluaran yang bersesuaian, serta
masa yang diperlukan bagi menghasilkan sebilangan jumlah tiang dan rasuk. Akhir
sekali, kesan kerosakan jentera yang digunakan serta sumber-sumber yang diperlukan
juga telah ditentukan di dalam kajian ini.
x
TABLE OF CONTENTS
Chapter Description Page
TITLE i
DECLARATION ii
DEDICATION vi
ACKNOWLEDGEMENT vii
ABTRACT viii
ABSTRAK ix
TABLE OF CONTENTS x
LIST OF TABLES xiv
LIST OF FIGURES xvi
LIST OF CHART xviii
CHAPTER 1 INTRODUCTION
1.1 Introduction 1
1.2 Problem Statement 3
1.3 Aim and Objectives of Study 3
1.4 Scope of Study 4
1.5 Significance of Study 5
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CHAPTER 2 LITERATURE REVIEW
2.1 Introduction 6
2.2 Industrialised Building System (IBS) 7
2.2.1 The Definition of IBS 7
2.2.2 The Feature of IBS 7
2.2.3 The Benefits and Limitation of IBS 8
2.2.4 IBS Components 9
2.2.5 IBS in Malaysia 10
2.3 Pre-cast Concrete 11
2.3.1 The Definition of Pre-cast Concrete 11
2.3.2 Advantages of Using Pre-cast Concrete 12
2.3.3 Pre-cast Concrete Production Stages 13
2.3.4 Stage (1): Preparation 14
2.3.5 Stage (2): Casting 15
2.3.6 Stage (3): Curing 19
2.3.7 Stage (4): Stripping and Demoulding 22
2.3.8 Stage (5): In-process Check 23
2.3.9 Stage (6): Lifting and Handling 23
2.4 Work Organization 24
2.4.1 All-purpose Team Method 25
2.4.2 Workstation Method 26
2.5 Production Line Layout 27
2.5.1 Flow Analysis and Activities
Analysis of Layout 28
2.5.2 Types of Flow Patterns 29
2.5.3 Types of Layout 31
2.6 Simulation 32
2.6.1 Simulation Definition 32
xii
2.6.2 Importance of Simulation 33
2.6.3 Advantages of Using Simulation 33
2.6.4 Disadvantages of Using Simulation 34
2.6.5 Simulation Software 35
2.7 Witness 2001 Software 36
2.7.1 Building a Simulation Model in
Witness 2001 36
CHAPTER 3 METHODOLOGY
3.1 Introduction 37
3.2 Production Stages Determination 37
3.3 Data Collection 39
3.4 Modelling and Simulation 40
3.5 Data Analysis and Discussion 41
3.6 Research Methodology Flowchart 41
CHAPTER 4 DATA COLLECTION
4.1 Introduction 43
4.2 Data Collection 44
4.3 The Production Line 44
4.3.1 Preparation Stage Data 45
4.3.2 Casting Stage Data 48
4.3.3 Treatment Stage Data 48
4.4 Production Plant Layout 51
4.5 Working Shifts 52
xiii
4.6 Witness 2001 Software 53
4.7 Applying Data 54
CHAPTER 5 RESULTS AND DISCUSSION
5.1 Introduction 56
5.2 Columns Production Line 56
5.2.1 Trial One 56
5.2.2 Trial Two 58
5.2.3 Trial Three 59
5.2.4 Trial Four (Increasing the Number
of Moulds 60
5.2.5 Trial Five (Increasing The Labour
and Machines 61
5.3 Columns Production Line and Working Shifts 63
5.4 Activities Breakdown 63
5.5 Beam Production Line 66
5.6 Beam Production Time and Working Shifts 70
5.7 Beam Production Line Breakdown 70
5.8 Production Lines Resources 72
CHAPTER 6 CONCLUSION AND RECOMMENDATIONS
6.1 Conclusion 75
6.2 Recommendations 77
REFERENCES 78
APPENDIXES 80
xiv
LIST OF TABLES
Table No. Title Page
4.1 The preparation of cement and raw
materials data 45
4.2 The preparation of steel reinforcement data 46
4.3 Mould preparation data 47
4.4 Placing steel cage and cleaning data 48
4.5 The casting stage data 48
4.6 Treatment stage data 49
4.7 The stages of concrete pre-cast
production elements 50
5.1 First trial results (columns production line) 57
5.2 Second trial results (columns production line) 58
5.3 Third trial results (columns production line) 59
5.4 Fourth trial results (columns production line) 61
5.5 Fifth trial results (columns production line) 62
xv
5.6 Columns production line attributes and the obtained time
(250 columns) 63
5.7 Comparison between times required to
produce Columns and times after breakdown 65
5.8 First trial results (beams production line) 67
5. 9 Second trial results (beams production line) 68
5.10 Third trial results (beams production line) 68
5.11 Fourth trial results (beams production line) 68
5.12 Fifth trial results (beams production line) 69
5.13 Sixth trial results (beams production line) 69
5.14 Beam production line attributes and the obtained time
(two production lines - 750 beams) 70
5.15 Comparison between the times required to produce
beams and time after breakdown 71
5.16 One shift work to produce 1000 columns and beams
in 50.5 days 73
5.17 Two shifts work to produce 1000 columns and beams
in 25.3 days 74
xvi
5.18 Two shifts work to produce 1000 columns and beams
in 16.8 days 74
LIST OF FIGURES
Figure No. Title Page
1.1 Pre-cast concrete beam and column 5
2.1 The fabricated reinforcement steel cage 14
2.2 Fixing the steel cage to the steel useable mould 15
2.3 All-purpose team work method 25
2.4 The workstation method 26
2.5 Communication links among product, process, schedule
and layout design 27
2.6 Basic flow pattern 30
2.7 Vertical flow pattern 30
2.8 Model building steps in Witness 2001 36
3.1 The flowchart of the stages of production pre-cast
concrete elements 38
xvii
3.2 The production line to be developed in the research 39
3.3 Research methodology flowchart 42
4.1 Concrete pre-cast columns and beams production
line layout 51
4.2 The start up window of Witness 2001 software 53
4.3 The six elements used to build the model 55
5.1 Columns production line simulation model 57
5.2 Breakdown window in Witness 2001 software 64
5.3 Beams production line simulation model 67
xviii
LIST OF CHARTS
Chart No. Title Page
2.1 The growth of Malaysian economy and [GDP] 11
5.1 The production line time for the trials one, two, and three 60
5.2 A comparison between trials three, four, and five 62
5.3 Effect of the activities breakdown on columns
production line time 65
5.4 Effect of the activities breakdown on beams
production line time 71
CHAPTER 1
INTRODUCTION
1.1 Introduction
The improvement of productivity and quality in building construction can be
attained only through intensive industrialization and building system process
development. The industrialization of building is most effective when as many as
possible of the building components are prefabricated in a plant with appropriate
equipment and efficient technological and managerial methods. Comprehensive
prefabricated elements that produced in the plant considerably reduce both the amount of
work onsite and dependence on the skill of available labour, on the weather, and on
various local constraints.
Historically, the industrial revolution affected the building sector in many ways.
Perhaps its most important affects were the introduction of structural steel and reinforced
concrete as main building materials in the second half of the 19th century. In addition,
reinforced concrete established itself as one of the major building materials because it
had some distinctive advantages over other prevalent material. Its production process was
2
relatively simple; it could be moulded into any shape and with proper processing yield an
attractive exterior surface.
One of the first applications of pre-cast concrete components was by W.H.
Lascelles in England in1878. Lascelles employed thin pre-cast concrete plates attached to
timber posts for use in walls and attached to concrete joints for use in floors of residential
cottages (Warszawski, 1999).
In Malaysia IBS started with the establishment of the Ministry of Local
Government and Housing in 1964. The Ministry focused then on the need to provide low
cost houses for the low income group. Towards this, housing programmes for the low
income people was launched and by 1966 the Ministry has launched two pilot projects in
two major cities namely Kuala Lumpur and Penang (AbdulRahim S., 2004).
During the five years of the Seventh Malaysian Plan, Malaysia built an amazing
one million dwelling, which constantly amazes visiting building professionals. The
Malaysian housing industry mass-produces more houses on per capita basis than any
other countries in the world. However, we must come to terms with harsh reality that
Malaysia is stuck at the bottom rung of the building technology ladder.
The information revolution started in the second part of the 20th century draws
from the use of computer for storing, processing, and transmitting information of
industrialized processes. The information revolution had a considerable effect on design
work in building and on some aspects of its administration and control in manufacturing
plant.
Actually, the applications of simulation in manufacturing and industrialized
building system are increasing rapidly. Consequently, simulation is a unique ability to
accurately predict the performance of complex processes which makes it ideally suited
for systems planning. In addition, simulation is emerging as an important developed tool
to enhance the production process performance of IBS.
3
Overall, a highly processing planning and an accurate layout of manufacturing
production lines are required to enrich the production activities of industrialized building
system elements.
1.2 Problem Statement
The production of Industrialized Building System elements at the prefabrication
plant involves many stages. One of the most important stages of IBS is the production
stage, especially if we talk about the pre-cast production as a part of IBS. In fact, this
stage is considered as one of the longest stages in term of time, processes, and activities.
The requirements of providing the appropriate shelter for every citizen enforced
multiple efforts to cover that increasing requirements and to enhance once again the
productivity of IBS elements. It is essential to reduce time and plan the resources and the
activities of the whole production processes. The need to adopt an optimized production
layout is essential to enhance the productivity, reduces the lead time and eliminates the
resources involved in the plant.
1.3 Aim and Objectives of Study
The aim of this study is to improve the performance of the production process at a
manufacturing plant to produce some of the pre-cast concrete elements as a part of IBS.
The word improvement involves reducing the production time, selecting the accurate
amount of resources, and identifying the optimum production line according to a specific
layout.
There are some specific objectives of this study, which are:
4
Propose an optimized layout of preparing raw materials and moulds, casting the
concrete, and curing the elements processes.
Estimate based on simulation test, the lead time, this is the time required to
produce IBS elements.
Determine the accurate number of resources such as labour and machineries
involved in manufacturing plant.
1.4 Scope of Study
The scope of this study is limited to the pre-cast concrete elements as a part of
IBS components production. The suggestion here is to produce 1,000 pre-cast concrete
elements namely: 750 beams and 250 columns. While the number of reusable steel
moulds is limited by 50 steel moulds to produce all the elements.
Accelerators admixtures are adopted in this research. The admixtures have been
assumed to be added during the concrete mixing process in order to hasting the hardening
of those elements, shortage the duration of the production process, and reducing the
number of moulds used.
Besides, using simulation software namely ‘Witness 2001’ program to build a
simulation model represent a production line of pre-cast concrete columns and beam.
Activities breakdown has been considered in this research. The effect of two
machines breakdown has been studied. These two machines are concrete compactor table
and concrete mixer.
Finally, there are some assumptions made in this study such as the production will
not to be interrupted due to lack of labours or insufficient supply of raw materials or
parts. The following figure shows the elements of IBS which are beam and column
5
produced by a pre-cast plant to build a typical house consist of 100 % prefabricated