Performance evaluation of a carousel configured multiple products flexible manufacturing system using Petri net

Abstract

This study presents a schematic approach to model, simulate and analyze the overall performance of an FMS, comprising a carousel layout surrounded by manufacturing and assembly cells capable to deliver a variety of multiple products. All manufacturing and assembly cells are consisting of multiple multifunctional production and assembly machines, served by material loading and unloading robots, connected through a material transporting conveyor. Inter-cellular and intra-cellular routing flexibility are employed in the system through production resources operational and breakdown modes. Colored Petri net tools are used to develop a compact, editable and deadlock-free flexible manufacturing system model reveals important information about dynamic behavior and system performance measures e.g.; throughput, mean cycle time, and work-in-process (WIP) with reference to material handling and supply system, production resources reliability and process execution input variables. Variation in input factors namely mean machining and assembly time, material loading and unloading time, number of operations between failure, repair time, parts inter-arrival time, conveyor speed and buffer capacity have shown a substantial effect on the system performance. The results indicate successful applicability of colored Petri net tools for modelling, simulation, and evaluation of carousel configured multiple products flexible manufacturing system. Further, the optimal solution represents a deep relationship between the different production modes and responses to maximize the performance of a carousel configured multiple products FMS.