Buffer Allocation Using 6 Steps Oba Method: A Case Study

Abstract

This paper utilized a simulation software to determine an optimal buffer allocation for any unpaced production line when a set of buffer quantity is known. The optimal buffer allocation will give the highest throughput rate (productivity) to the production line. From the simulation result, a trend of relation between mean processing time (μ) trend of the stations in the production line and buffer allocation configuration of the buffer slots were studied. It was concluded that for any unpaced production line, the best throughput rate of the production line will be obtained if the buffer allocation configuration follow the mean processing time (μ) trend. By applying this concept, a mathematical relation was formed results in a development of a technique called 6 Steps OBA (optimal buffer allocation) method . In order to validate the result from this 6 Steps OBA method, a case study was carried out in one of the multinational electronics company in Malaysia (Company S). An unpaced and u-unbalanced production line was selected and this line was producing a product which is known as model A. In this production line, a few possible buffer allocations quantity were allocated on each buffer slots including buffer allocation suggested by 6 Steps OBA method. For each buffer allocation possibilities, the actual production line productivity (throughput rate) was recorded and compared to validate that the best line throughput rate was the buffer allocation suggested by the 6 Steps OBA method. From the overall result, it was proven that the 6 Steps OBA method will give a maximum throughput rate to a production line.