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Volume: 10 2023 Issue: 4 Pages: 557-565 ISSN 1339-5629
Imp o ing alloca ion and layou in p oduc ion logis ics
Ma in S aka, Pe e Kacma y, Pe Bes a
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h ps://doi.o g/10.22306/al. 10i4.434 Recei ed: 05 June 2023; Re ised: 26 No . 2023; Accep ed: 10 Dec. 2023
Imp o ing alloca ion and layou in p oduc ion logis ics
Ma in S aka
Technical Uni e si y o Košice, Facul y BERG, Ins i u e o Logis ics and T anspo , Pa k Komenského 14, 04384
Košice, Slo ak Republic, EU, ma in.s aka@ uke.sk
Pe e Kacma y
Technical Uni e si y o Košice, Facul y BERG, Ins i u e o Logis ics and T anspo , Pa k Komenského 14, 04384
Košice, Slo ak Republic, EU, pe e .kacma y@ uke.sk (co esponding au ho )
Pe Bes a
VŠB - Technical Uni e si y o Os a a, 17. lis opanu 21/1572, 708 33 Os a a-Po uba, Czech Republic, EU,
pe .bes a@ sb.cz
Keywo ds: alloca ion and layou , logis ics, sys em, wo kplaces, p oduc ion.
Abs ac : The a icle deals wi h he p incipled solu ion o alloca ion and layou o wo kplaces in a company p oducing o
a ie y building componen s. Alloca ion and layou a e e y impo an a eas o ensu ing he e icien ope a ion o
companies engaged in p oduc ion as well as in comme cial ac i i ies. Bo h alloca ion and layou solu ions ha e a s a egic
impo ance o companies. The in es iga ed company p oduces cons uc ion me al elemen s as a pa o mode n
cons uc ion echnologies. The p oblem is ela ed o he cons an imp o ing ac i i ies in he company in o de o ensu e
i s compe i i eness on he ma ke . The p oduc ion p ocess o cons uc ion me al elemen s consis s o wo kplaces such as
cu ing, d illing, milling, welding and gal anizing. Wo kplaces o inspec ion and loading o inished p oduc s a e non-
p oduc ion. The solu ion o he p ojec was aimed a s eamlining ac i i ies in e ms o logis ics, ma e ial lows as well
as in e ms o sa e y.
1 In oduc ion
While sea ching o possibili ies o inc ease he
p oduc ion capaci ies o he manu ac u ing o building
elemen s in he in es iga ed company, he p oblem a ose
how o e ec i ely alloca e and place p oduc ion
equipmen , wa ehouses, bu e s, o implemen anspo
ou es in hei p oduc ion hall whe e building elemen s a e
made. This is also a ended by s eamlining o he layou o
p oduc ion and in e ope a ion equipmen , s o age and
in e s o age a eas in he hall o mee echnological, sa e y
and capaci y equi emen s.
The p ocedu e o e ec i e solu ion o alloca ion and
layou consis s o he ollowing pa s:
• Measu emen o p emises, p oduc ion machines,
equipmen and wo kplaces.
• Analysis o spa ial pa ame e s, possibili ies and
limi a ions, machines and equipmen , ma e ial inpu s
and ou pu s o p oduc s, ma e ial lows in a space,
s o age possibili ies and legisla i e egula ions and
s anda ds.
• Design o logis ic elemen s, handling uni s o he
needs o e ec i e ac i i ies in p oduc ion.
• Design o he alloca ion and layou o p oduc ion
wo kplaces, machines and equipmen o he
placemen o ma e ial a he en ance and du ing
p oduc ion, he loca ion o he en ance and exi o
p oduc s o gal anizing and he loca ion o inished
p oduc s.
•
P ocess-e icien s o age o semi- inished p oduc s,
e icien anspo ou es wi hin he p oduc ion hall,
c ea ing pa hs o he sa e y mo emen o wo ke s.
2 Li e a u e e iew
Alloca ion and layou a e an impo an elemen o he
e ec i e inc ease o capaci ies in logis ics. The impo ance
o alloca ion and layou solu ions is s ill he same o any
manu ac u ing company. Many companies app oach he
solu ion o alloca ion and layou sys ema ically, bu some
make layou mo e e icien only o e ime, based on hei
acqui ed expe ience and knowledge. The au ho s
Gabajo á, e al. s a e in hei publica ion ha : “Designing
a wo kplace may be a challenging ask. I is impo an o
make su e ha he new wo kplace will p e en unnecessa y
esou ce was e, bu also c ea e a sa e wo king en i onmen
o employees” [1].
Solu ion o alloca ion and also, wi hin ce ain
limi a ions, layou is a s a egic solu ion ha will be
implemen ed in p ac ice o se e al yea s. Fo his eason,
he solu ion mus be app oached wi h all se iousness.
Alloca ion is a p ocess ha esul s in he loca ion o he
company, wa ehouse, p oduc ion, machine and e e y hing
ha can be alloca ed on an a ea o in a speci ic space [2].
In e ms o e ec i e alloca ion and layou solu ions,
many me hods and p ocedu es can be used. The au ho s
K ono á, e al. used, o example, he Clus e Analysis
me hod o sol ing layou , which is desc ibed in hei wo k
[3]. Many au ho s use compu e simula ion as an e ec i e
means o sol ing alloca ion and layou p oblems [4-8].
Acco ding o au ho s G zná , e al. “The one o he mos
impo an asks in designing is de ailed design. In his
p ocess, he inal layou o he elemen s, oge he wi h hei
demands o space in a common 2D and 3D iew, plays a
a he complex ma e ” [9].
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One o he popula me hods o sol ing o he
men ioned p oblem is he CRAFT me hod (Compu e ized
Rela i e Alloca ion o Facili ies Technique), which
belongs o he g oup o enume a i e me hods and gi es he
op imal solu ion unde de ined condi ions and cons ain s.
The applica ion o he abo e me hod is p ac ically
desc ibed in he pape s [10-13].
The e a e a numbe o p ocedu es and me hods ha can
be used o sol e a s a egic decision o alloca ion and
layou in p ac ice. The e o e, he au ho s o his pape ,
when w i ing he a icle, limi ed hemsel es o he ac ual
side and de ining he p inciple p ocedu es ha can be used
in gene al in he subjec ma e wi h a p ac ical
demons a ion o he solu ion o he speci ic ask.
3 Me hodology
Inapp op ia e alloca ion and layou o p oduc ion
acili ies leads o ine icien logis ics, p olonged ma e ial
lows, longe anspo imes and an inc eased need o
in e media e wa ehouses (bu e s) o ma e ials, semi-
inished and inished p oduc s. All his inc eases he cos s
associa ed wi h he p oduc ion i sel . Alloca ion and layou
e iciency concen a es capaci y, ma e ial, economic,
sa e y and echnological ules in o de o minimize
subjec i e app oaches in he alloca ion and layou o
wo kplaces and p oduc ion acili ies.
The solu ion o he p oblem applies a p ojec app oach
wi h he basic pos ula es o logis ics such as he sys ems
app oach, algo i hmic hinking, coo dina ion, planning and
global op imiza ion, which a e con ained in he pa s
o ming he me hodology:
• The global objec i e o he p ojec solu ion is o
inc ease p oduc i i y, inc ease he capaci y u iliza ion
o equipmen , educe cos s and inc ease sa e y a
wo k.
• To analyse he ac ual s a e o layou o p oduc ion and
in e ope a ion equipmen , s o age and in e s o age
a eas, including palle s, c a es and boxes ha o m
small bu e s.
• To de ine and desc ibe he c i e ia and p inciples o
he deploymen o p oduc ion and in e ope a ion
equipmen , s o age and in e s o age a eas and bu e s
in he p oduc ion hall, whe e building elemen s a e
made.
• To de elop a sys em o deploymen and o p opose
deploymen op ions aking in o accoun he de ined
c i e ia.
• To design logis ics elemen s, handling uni s o he
needs o s eamlining ope a ions in p oduc ion.
• To de ine he c i e ia o he selec ion o he mos
e icien a ian .
• To design an e icien layou o p oduc ion and
in e ope a ion equipmen , s o age and in e s o age
a eas and bu e s by means o a sys em solu ion unde
de ined condi ions.
4 Resul and discussion
Conside ing he new ends in building indus y, he
company is ocused on he de elopmen and p oduc ion o
cons uc ion elemen s ha se e bo h o ensu e and o
implemen cons uc ion ope a ions and p ocesses. The
p io i y o he p oduc ion o cons uc ion elemen s is a
sus ainable s a e o e ec i ely spen cos s o hei
p oduc ion, which is achie ed by: s eamlining logis ics
p ocesses, s eamlining p oduc ion p ocesses and using
sui able echnological equipmen and sui able ma e ials as
well as hei s eamlining alloca ion and layou .
4.1 P esen a ion o he o e ed se ices
Since i s es ablishmen , he company has been engaged
in he de elopmen and p oduc ion o i on building
elemen s o i s own cons uc ion. In addi ion o he
p oduc ion o i on cons uc ion elemen s, he company
o e s se ices in he ield o p ocessing and
implemen a ion o ope a ions ela ed o mechanical
p oduc ion and p ocessing o i on elemen s such as shee s,
" oxo s" ( ein o cing s eel), s eel ba s wi h a ious p o iles
(I, L, T, U, □, ○, e c.), pipes, p isms, e c. Classi ica ion o
o e ed se ices is ollowed:
• Cu ing - ci cula saw, au oma ic band saw, plasma
cu e .
• Ca ing by plasma.
• D illing - manual, s and d ill, au oma ic.
• Tu ning.
• Th ead milling.
• Welding - elec ic a c welding in a p o ec i e
a mosphe e o ine gas, spo welding.
• Bending - manual, machine.
4.2 Ma e ial low analysis
The e a e 6 main ma e ial lows in he company
(Figu e 1), which a e cha ac e ized by pa s wi h inal
p oduc ion o wi h p oduc ion o he inaliza ion o
building elemen s.
The ma e ial low analysis shows ha ma e ial lows
h ough he p oduc ion hall acco ding o he p oduc ion
echnology o each p oduc . In he p oduc ion o indi idual
p oduc s, many o he p oduc ion ope a ions a e iden ical
(cu ing, welding, d illing, milling, cleaning and e-d illing
a e gal anisa ion, s o age, a ixing ID labels). The
p oduc ion ope a ions ha e hei own p oduc -speci ic
pa ame e s, which c ea es conside able a iabili y in e ms
o equipmen se -up and he e o e handling ime
equi emen s, as well as space equi emen s o he s o age
o ma e ials a he s a o p oduc ion, wo k-in-p ocess
ma e ials, semi- inished p oduc s, p e-gal anising o
gal anising p oduc s, and inished p oduc s.
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Volume: 10 2023 Issue: 4 Pages: 557-565 ISSN 1339-5629
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Figu e 1 Main lows o ma e ial, semi- inished p oduc s and p oduc s
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4.3 Iden i ica ion o de iciencies in e ms o
ma e ial lows
The e a e ollowing indings and sho comings ound
om he sys em analysis o he company's ac i i ies
ocused on he alloca ion and layou o p oduc ion
equipmen , ma e ials, semi- inished p oduc s, p oduc s,
was e and ma e ial lows:
• The company places i s wo k-in-p og ess, semi-
inished p oduc s, p oduc s and was e in a la ge a ea
wi hin he p oduc ion a ea (Figu e 2).
• Ma e ials in p oduc ion, semi- inished p oduc s,
p oduc s and was e a e s o ed in a ious non-
s anda dised "boxes o con aine s" (pape and
polys y ene boxes, plas ic c a es, i on con aine s,
bucke s, wooden boxes, e c.), many o which a e no
sui able in e ms o s eng h, echnically and sa e y.
• "Con aine s" wi h p oduc ion ma e ial, semi- inished
p oduc s, p oduc s and was e a e placed on se e al
di e en ypes o palle s.
• Down ime on special p oduc ion equipmen , such as
au oma ed d illing machines, caused by lack o
quali ied pe sonnel and p oduc ion planning.
• Ine icien ly used space a ound he plasma cu e o
blocked space a ound he plasma cu e wi h a ious
ma e ials and p oduc ion was e (Figu e 3).
• Ine icien use o space o he dispensing and
ecei ing o semi- inished goods and p oduc s.
• C ossing o ma e ial lows in he p oduc ion hall.
• Repe i i e loading and unloading o semi- inished
and inished p oduc s in and ou o c a es, on and o
ehicles.
Figu e 2 Loca ion o ma e ials, semi- inished p oduc s, p oduc s
and was e in he p oduc ion hall
Figu e 3 Ine icien ly used space a ound he plasma cu e in he
p oduc ion hall
4.4 Design concep o he alloca ion and layou
o he wo kplace and p oduc ion acili ies
The e is ad isable o implemen he ollowing
measu es o ge he ope a ion o wo k in he p oduc ion hall
mo e e icien , which include p oduc ion and
in e ope a ion equipmen , s o age and in e s o age a eas,
including palle s, c a es and boxes and bu e s:
• To in oduce s anda dised palle s in o he p oduc ion
p ocess.
• To in oduce s anda dized palle me al boxes and
handling uni s in o he p oduc ion p ocess.
• To in oduce s anda dized palle acks, s acking o
palle s in o he p oduc ion p ocess.
• To in oduce s o age acks and a shel s acke o
me al shee s (pla es) in o he p oduc ion p ocess.
• To s eamline he layou o wo kplaces while
espec ing echnical, echnological and sa e y
condi ions and cons ain s.
As many non-s anda dised c a es, boxes, as well as
di e en ypes o palle s a e used in p oduc ion, i is
necessa y o in oduce s anda dised palle s, c a es and
boxes o s eamline handling, mo ing and s o age
ope a ions.
4.4.1 S o age - handling uni s
The design o handling uni s o he s o age o
ma e ials, semi- inished p oduc s, wo k-in-p og ess and
inished p oduc s is based on he exis ing dimensions o he
mos common used eu o palle s 800 x 1200 mm (Figu e 4),
in addi ion o specialised anspo uni s. The heigh o he
eu o palle s is se a 144 mm acco ding o STN 26 9110
s anda d. I s possible load capaci y is as ollows (acco ding
o he men ioned s anda d):
• 1 000 kg, i he load is a bi a ily dis ibu ed on he
uppe su ace o he palle ;
• 1 500 kg, i he load is e enly placed on he op
su ace o he palle ;
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• 2 000 kg, i he load in solid o m i s e enly ac oss
he en i e uppe su ace o he palle ;
• 4 000 kg an addi ional load when s acking, i he load
is on a palle adjacen , ull la on a ho izon al and
igid su ace.
Figu e 4 S anda d Eu o palle size 800 x 1200 mm
The design o he in e nal handling uni (he ea e
e e ed o as he box) o use wi h a s anda d Eu o palle
(bu also wi hou i ) is 600 x 400 x 200 o 400 mm (l x w x
h) o small-sized elemen s (Figu e 5). Acco ding o he
abo e palle and enclosu e dimensions, he shape and
especially he dimensions o he handling boxes and he
a angemen on palle s (Figu e 6) a e designed o be 1200
mm x 800 mm o 1200 mm x 1000 mm.
Figu e 5 Design o handling boxes and hei dimensions
Figu e 6 S acking o p oposed boxes on s anda dised palle s
4.4.2 Alloca ion and layou o wo kplaces in
compliance wi h echnical, echnological and
sa e y condi ions and es ic ions
The solu ion and design o he alloca ion and layou o
wo kplaces, p oduc ion and in e ope a ion equipmen ,
s o age and in e s o age a eas and bu e s mus ake in o
accoun he equi emen s and es ic ions de ined by
legisla ion, Slo ak echnical s anda ds, manu ac u ing
echnology and obse e sa e y a wo k.
The basic cons ain s and equi emen s ha need o be
aken in o accoun when designing he layou a e:
• Co ido s wid hs and space a ound machine y and
equipmen .
• Wid h o ansi ion aisles.
• Escape ou es.
• Taking in o accoun he sequence o lows o
ma e ials, semi- inished and inished p oduc s.
• The needs de e mined by he manu ac u ing
echnology.
• Wo ke s equi emen s.
• Limi a ions due o he echnical condi ion o he
p oduc ion hall.
The layou designs (Figu e 7, Figu e 8) o wo kplaces,
p oduc ion and in e ope a ion equipmen , s o age and
in e s o age a eas and bu e s a e based on he ollowing
condi ions:
• The a ea a ound he headqua e s (Con ol and
Pe sonnel Cen e), has o o m a sa e zone o he
p oduc ion loo pe sonnel. No o kli o o he
ehicles shall en e he zone, any o he elemen s
es ic ing mo emen such as ma e ials, shee s,
cu ings, p oduc s, e c. canno be placed in he zone.
The zone wi h he en ance and exi a he Con ol
Cen e will o m one o he main g een escape ou es.
• The ansi ion co ido in he middle o he hall mus
be clea , wi hou se ious es ic ions. In addi ion o
he ma e ial en ances and exi s, he co ido also
se es as an escape ou e, loca ed in he cen e o he
hall be ween he wo opposi e doo s. I mus be kep
clea om he poin o iew o i s unc ionali y and o
ensu e he con inui y o ma e ial lows, supply and
sa e y.
• The unc ional o m o he p oduc s is gi en by he
welding wo kplaces. Welding p ocesses o m he
essence o p oduc ion, i is ad isable o cen alize
hem and place hem among he columns in he
p oduc ion hall wi h dimensions pe one welding
wo kplace o abou 4 x 4 me e s. The ma e ial lows
a e concen a ed a he welding wo kplaces, which
ha e hei own ma e ial inpu s and ou pu s ha a e
dimensionally he e ogeneous and as well as hey a e
ela ed o each o he in e ms o echnological
p ocesses. Fo hese easons, i is ad isable ha he
wo kplaces should ha e dimensional a iabili y on
bo h, he inpu and ou pu sides o he wo kplace.
• The p oduc ion ope a ions, wi h hei echnical
suppo , which o m he main con en o he
p oduc ion and a e ca ied ou egula ly, consis ing o
se e al ypes o simila o iden ical equipmen
(d illing, cu ing), will be cumula ed wi hin hei
sec ions. This measu e can ha e he syne gis ic e ec
o inc easing p oduc ion and he subs i u abili y o
p oduc ion equipmen in one sec ion, wi hou he
need o unnecessa y ma e ial ans e s.
• P oduc ion ope a ions, wi h hei echnical suppo ,
which do no o m he main con en o p oduc ion and
a e ca ied ou spo adically, will be loca ed a he end
o a he wall in he p oduc ion hall ( u ning, h ead
cu ing, milling).
600
400
400
600
400
2
0
0
800
1000
1200
Box4Box3
Box2Box1
Box3
Box5
Box4
Box1
Box2

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• I is necessa y o use s anda dized logis ic acks as
well as a ailable, non-s anda d bu sa e ee a eas,
e.g. on he oo o a ool-wa ehouse-shel e in he
p oduc ion hall o he needs o e icien loca ion and
s o age o ools, empla es, ma ices and o he
elemen s o p oduc ion needs.
• I is necessa y o use he s o age o he shee s in a
specialised sel -suppo ing ack, which is no
connec ed o he suppo ing columns in he hall (as i
was be o e) o he e icien and sa e placemen o he
s eel pla es (shee s), o he plasma cu e zone. This
solu ion opens up he possibili y o a iabili y o he
loca ion o he shee me al s o age in a di e en
loca ion o he p oduc ion hall columns.
Figu e 7 Design o he sec ion layou in he p oduc ion hall, schema ic ep esen a ion
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Figu e 8 Design o he sec ion layou in he p oduc ion hall
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5 Conclusions
The ac ual solu ion o alloca ion and layou has i s own
laws, ules, echniques, p ocedu es and me hods. In many
scien i ic pape s, i is possible o ind p ocedu es whose
solu ion is based on common egula i ies such as he use o
compu e simula ion [14-17], he use o modelling and
CAD sys ems [18-21], he use o mul i-c i e ia decision
making [22-25] o o he app oaches o sol e e icien
alloca ion and layou [26-30].
The in en ion o he alloca ion and layou solu ion was
o design an e icien layou o me al building elemen s
p oduc ion wo kplaces based on hei ope a ions and
p ocesses as well as logis ical pa e ns o he needs o
p oduc ion e iciency and layou o p oduc ion and
in e ope a ion equipmen , s o age and in e s o age a eas
and bu e s in he p oduc ion hall, while mee ing he
de ined echnical, echnological, sa e y and op imiza ion
c i e ia.
The concep ual solu ion o alloca ion and layou o he
company engaged in he p oduc ion o me al building
elemen s b ough sa ings in he o m o 30% educ ion o
c ossing ma e ial lows, inc eased sa e y a wo k, c ea ed
wo kplaces ha we e a anged acco ding o he p ocedu e
de ined by he echnology o p oduc s manu ac u ing,
which ensu es smoo h ma e ial lows, sa e zones wi hou
mechaniza ion ha we e de ined o wo ke s,
s anda diza ion was in oduced in e ms o echnical,
p oduc ion and logis ic means, small bu e s loca ed in a
conside able a ea in he p oduc ion hall we e elimina ed
and o he places wi hou p ac ical use we e elimina ed oo.
Acknowledgemen
The submi ed pape is a pa o he p ojec 010TUKE-
4/2023 - Applica ion o educa ional obo s in he p ocess
o eaching he s udy p og am indus ial logis ics.
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