Modular redesign methodology for improving plant layout

Abstract

This research aims to show how redesigning a product, specifically modular redesign, may lead to changes in factory internal plant distribution, increasing the production levels of a company. This increase was achieved by implementing a methodology that will be discussed in this article and that includes the whole redesigning process of products, from disassembly to plant layout. For this research, tools used include functional analysis, design structure matrix, Theory of Technical Systems, design for assembly, diagram of operations and some management concepts of the platform of a modular product. To illustrate the implementation of the proposed methodology, a blender was chosen as a study case, in which, after applying the methodology, an increase in modularity, in the efficiency of design and in the efficiency of assembly, as well as a reduction in assembly times were obtained. Finally, with the new proposed plant layout, a significant increase in the production of blenders was successfully obtained.