Design and analysis of a virtual factory layout

Conventional analytical systems are capable of providing statistical evaluation of targeted factory design feasibility. However, with this system, designers cannot get the feel for the actual setting of that factory design. With the advent of computer-aided design (CAD) system these problems are solved to a certain extent. CAD software allows the user to build models/templates and move them around on the screen and the analysis can be done in few hours. Re-layout could also be easily accomplished. But the drawback of the computer-based system is that they provide the user with a two-dimensional (2D) view of the layouts, which are not easy to visualise, understand and evaluate. With the virtual reality (VR) environment, a designer can have the feel of the actual setting of the factory. Inside the 3D environment, the depth perspective could be achieved which is not possible in a 2D view. This also provides better interactions than 2D system. Potential problems such as safety issues, aisle and other layout problems can be visualised and modified by applying plant layout problem solving techniques. Re-layout of the existing factory layout can be done until satisfactory result is obtained. This paper describes how a factory layout can be designed and analysed in 3D virtual environment by applying factory layout problem solving techniques. An alternative layout was achieved and a new aisle system was introduced. Resulting material handling distance from department to department was found to be less after implementing the new aisle system in the factory.