Production Line Capacity Research Articles

Mixed assembly line rebalancing: A binary integer approach applied to real world problems in the automotive industry

Industrial organizations have increasingly sought to optimize the resources needed for the manufacture of its products from the competition, in order to maintain their profit margins. The search for balance of resources and balanced distribution of tasks in various types of industrial environments is called balancing. When adjustments are made and adequacy of an assembly line that is already in operation, this process is called rebalancing. This paper presents a case study involving a problem of rebalancing of automotive assembly line in an environment of arbitrarily mixed models of products, also known as mix. The proposed procedure for solving the rebalancing in the company in question is based on Binary Integer Programming, in particular the branch and bound algorithm. For comparison, we used a heuristic method based on precedence diagrams for solving the rebalancing of lines. To evaluate the results obtained between the two procedures were used performance indicators such as number of workstations created, average load of work and level of unbalance. The proposed algorithm has resulted in significant improvements in the production line capacity.

Simulation and Optimization of the Camshaft Production Line Based on Petri Net

With the development of scientific and technology, the automotive industries competition is becoming more and tougher. The camshaft production system is an important part of the engine manufacturing. The production line productivity and characteristic are affected by many practical factors of the workshop. It’s a complex discrete manufacturing system somehow. In this paper, the production line model is presented based on Petri net. Then the mapping relationship is established between the Petri net model and the eM-Plant discrete system model. The discrete simulation model of production line is constructed by using eM-plant software. Based on the simulation, the reasonable simulation experimental are carried out with the determined simulation boundary and objectives under the different input conditions such as orders, the working stations' processing time, the working stations’ fault distribution, and the production line layout. The simulation experimental results are discussed on condition that the shifts, equipment operation condition, production line capacity and WIP in detail. These results could provide the theory basis for decision-making of the production plan of the automotive industries.

Stochastic approximations for optimal buffer capacity of many-station production lines

Probabilistic processing times, times between breakdowns and repair times make the amount of stock in buffers between stations in production lines behave as a stochastic process. Too much or too little buffer stock reduces system economy and efficiency, respectively. We obtain optimum buffer capacities and initial stock levels for production lines employing a mathematical random walk approach based on the maximum and minimum values of a stochastic process in a time window. Two approximations are developed, each useful under different risk-acceptance assumptions. Simulation results populate the equations. A motivating case study from a discrete part manufacturing line, including an example of using regression on the simulated results, is presented.

Serial Agile Production Systems with Automation

To gain insights into the design and control of manufacturing cells with automation, we study simple models of serial production systems where one flexible worker attends a set of automated stations. We (a) characterize the operational benefits of automation, (b) determine the most desirable placement of automation within a line, and (c) investigate how best to allocate labor dynamically in a line with manual and automatic equipment. We do this by first considering two-station Markov decision process models and then studying three-station simulations. Our results show that the capacity of production lines with automatic machines can be significantly lower than the rate of the bottleneck. We also show that automating a manual machine can have a dramatic effect on the average work-in-process (WIP) level, provided that labor is the system bottleneck. Once a machine becomes the bottleneck, the benefits from further automation are dramatically reduced. In general, we find that automation is more effective when placed toward the end of the line rather than toward the front. Finally, we show that automation level increases the priority workers should give to a station when selecting a work location.

An efficient model for multifamily lot-sizing and scheduling: application to a real life problem

A multifamily lot-sizing and scheduling model is developed for a production environment where the production line capacity is a critical factor. Since the capacity is limited, judicious selections of family cycle times and which products of a family should be produced in a given cycle are critical in avoiding shortages. The model can be implemented using available spreadsheet programs and can be easily understood by production planners. The model was applied to a real life problem at a leading manufacturer of hygienic products. With respect to their current practice, the model resulted in a solution that was uniform in application and reduced total costs by 16%. The model was also compared against Brown's model in an uncapacitated environment. Results were encouraging, as the model performed as well as Brown's model and even better in some cases. The proposed model has an advantage over Brown's since it results in common cycle times for all product families making scheduling and controlling easier.

Decision Matrix For The Panel Production Line Technological ImprovementPolicy Definition

Technological improvement in comparison to technological renewal, presents a greater project challenge, because it requires a more detailed approach in terms of defining input variables to meet user demands. In context of such improvement, denominated as refitting of the panel production line within, one of the major Croatian shipyards, the authors explored various methods to determine technological improvement policy. They used a functional breakdown concept for panel production line equipment components. Refitting includes the overall replacement of driving operations on the panel production line in general, that represents objects of technological improvement. To ensure a systematic approach to define improvement policy, and to consider all relevant parameters and user requirements, the decision matrix method is applied. Due to the application of such method, cause-effect relations were established and absolute and relative priorities of observed parameters were defined. Furthermore, all panel production line characteristic and driving operations have been systematically analysed with the objective to assure required capacities and high quality of finished panels. The authors emphasize that for a successful accomplishment of refitting goals, conventional treatment of panel production line capacity, based on average panel, is not appropriate, Fafandjel [l]. Such capacity definition cannot provide information of actual throughput of stations, or technical-functional characteristics of functional units. Therefore, the authors are suggesting the appliance of panel with characteristics that makes it a most complex one for fabrication on the particular panel production line, instead of an average panel, which is defined as a standard one.

Barrel plating

Barrel plating has distinct advantages: the ability to finish a larger variety of work and producing a greater volume of work for a specified time period over a rack-type finishing line. By incorporating as many aspects of the previously mentioned information as possible, the capacity and capability of a barrel finishing production line can be optimized.

Barrel plating

Barrel plating has distinct advantages: the ability to finish a larger variety of work and producing a greater volume of work for a specified time period over a rack-type finishing line. By incorporating as many aspects of the previously mentioned information as possible, the capacity and capability of a barrel finishing production line can be optimized.

Barrel plating

Barrel plating has distinct advantages: the ability to finish a larger variety of work and producing a greater volume of work for a specified time period over a rack-type finishing line. By incorporating as many aspects of the previously mentioned information as possible, the capacity and capability of a barrel finishing production line can be optimized.

Barrel plating

Barrel plating has distinct advantages: the ability to finish a larger variety of work and producing a greater volume of work for a specified time period over a rack-type finishing line. By incorporating as many aspects of the previously mentioned information as possible, the capacity and capability of a barrel finishing production line can be optimized.

A Four-Day Study Helps Home Building Move Indoors

By simulating Glaize Components' new wall panel production line, we sought to increase the capacity of this advanced CAD/CAM flexible manufacturing system. Developing the model was complicated by healthy industry skepticism, a short time window, and limited resources. By adhering strictly to a condensed, yet comprehensive project plan and using high quality animation, the project team overcame these barriers. Simulation results suggested that Glaize could increase production line capacity eight percent by resequencing, alternating between interior and exterior panels. Gaining confidence from the simulation results, Glaize tried alternating panels, and it worked. The change has yielded a seven to 10 percent increase in line capacity with minimal increases in capital and labor.

Staff oriented simulation of new production systems

In order to meet technological and economical demands, industrial enterprises have to reconsider their organizational structures. Especially on the shop floor level, new types of work structures are required to increase flexibility and productivity. However, the effects of such changes on certain indicators (e.g. dynamic capacity of production lines, lead time of jobs) can hardly be calculated during the planning processes. For this reason the use of simulation programs is often recommended.In this paper a simulation program is presented which allows us to investigate the effects of various numbers and qualifications of personnel employed in a specific work shop. For this purpose, the program incorporates three different types of input data concerning the production program, the equipment and the qualification of personnel. Due to this, results can be achieved on the loading of the personnel as well as the machines and the dynamic capacity of the production system. The economical results can be evaluated in terms of cost. The practical use of this simulation program is shown by an example concerning a special planning case.