Papers by Keyword: Manufacturing System Design

Abstract: Proper selection of personnel constitutes a frequent challenge for the management of many enterprises. In this paper the above problem has been defined using three objective functions which required simultaneous optimisation. To solve this problem, computer modelling based on Petri nets was proposed. The model was subjected to iterative computer simulation, during which various variants of workstation assignment were tested. This resulted in the emergence of a variant which best fulfilled the assumed optimisation criteria.

Abstract: This paper analyses the production line layout of the manufacturing system design to identify the key performance and to improve the production performance of a bicarbonate beverage production company by using simulation modelling approach. Due to our approach, a simulation model of the real production line layout and new improved production line layout was developed. The key performance indicators of the manufacturing system were evaluated using Arena software. The analysis of the indicator values revealed an improvement within new improved model compare to the real production line layout. The percentage errors for simulation of actual model with new improved model give an improvement percentage of 3.91% for Model A and 44.1% for Model B. All models that have been developed in this research by using the Arena software were also being validated. On the basis of these findings, factory production line layout can be simulated by using the Arena software that enhances the result for further improvement.

Abstract: This paper reports the practical experiences made with extending the Value Stream Mapping (VSM) approach to the comprehensive design of a lean manufacturing system for the series production of sheet metal cable tray systems. The use of VSM for analyzing the production of repetitive units has proven to be successful in different industries. It is based on a classification of all products into product families and creates one current and future state map for each product family. This approach and the related guidelines for future state optimization are very helpful but not sufficient for a comprehensive manufacturing system (re) design, because the relation between product families value streams, the overall material flow optimization, as well as the segmentation and layout of factory remains unclear. Thus, the purpose of this paper is to develop a design procedure based on the investigation of an industrial case that allows the integrated optimization of the single value streams, their compilation in material-flow optimized production segments, and finally the (re) design of production logistics and factory layout. The findings of this research are limited due to the focused nature of a case study based research. However, the obtained results encourage assuming its transferability to similar problems.

Abstract: The complexity of a manufacturing system is determined by the uncertainty in achieving the system’s functional requirements and is caused by two factors: by a time-independent poor design that causes a system-inherent low efficiency (system design), and by a time-dependent reduction of system performance due to system deterioration or to market or technology changes (system dynamics). To maximize the productivity of a manufacturing system, its entire complexity must be reduced. Many valid methods have been developed so far addressing different single manufacturing and quality issues. But to continuously increase the productivity of a manufacturing system within a turbulent environment its entire complexity must be reduced. This requires a holistic understanding and knowledge about the system. To reduce a system’s complexity, its subsystems should not overlap in their contribution to the overall system’s functionality, they must be mutually exclusive. On the other hand, the interplay of system’s components must be collectively exhaustive in order to include every issue relevant to the entire system’s functionality. This paper introduces a concept for complexity reduction in manufacturing systems with the help of Nam P. Suh’s Axiomatic Design principles. In a first step, time-dependent elements are separated from time-independent elements. To eliminate the real complexity of the time-independent elements (so called manufacturing modules), a set of alternative design parameters are defined that fit the system range of the manufacturing module’s set of functional requirements. To reduce the time-dependent combinatorial complexity, a methodology is proposed to systematically define an entire manufacturing system’s functional requirements within very short times in order to guarantee a fast reconfiguration of the system considering internal and external system dynamics. With the help of practical examples and the obtained results, the validity of the approach is illustrated.