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n South African Journal of Industrial Engineering - Managing bottlenecks in manual automobile assembly systems using discrete event simulation : case study

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Abstract

Batch model lines are quite handy when the demand for each product is moderate. However, they are characterised by high work-in-progress inventories, lost production time when changing over models, and reduced flexibility when it comes to altering production rates as product demand changes. On the other hand, mixed model lines can offer reduced work-in-progress inventory and increased flexibility. The object of this paper is to illustrate that a manual automobile assembling system can be optimised through managing bottlenecks by ensuring high workstation utilisation, reducing queue lengths before stations and reducing station downtime. A case study from the automobile industry is used for data collection. A model is developed through the use of simulation software. The model is then verified and validated before a detailed bottleneck analysis is conducted. An operational strategy is then proposed for optimal bottleneck management. Although the paper focuses on improving automobile assembly systems in batch mode, the methodology can also be applied in single model manual and automated production lines.

Lotgrootteproduksielyne kom baie handig te pas wanneer die vraag vir elke produk matig is. Lotgrootteproduksielyne word egter gekenmerk deur hoë werk-in-prosesvoorraad, verlore produksietyd wanneer modelle verander en verlaagde buigsaamheid wanneer dit kom by die verandering van die produksietempo's as produkaanvraag verander. Gemengde model-produksielyne kan egter verlaagde werk-in-prosesvoorraad en verhoogde buigsaamheid bied. Die doel van hierdie artikel is om te illustreer dat 'n handgedrewe voertuigmontering-sisteem geoptimiseer kan word deur bottelnekke te bestuur deur hoë werkstasie-benutting te verseker, die toulengtes voor werkstasies en werkstasiestilstand te verminder. 'n Gevallestudie uit die motorindustrie word gebruik vir data-insameling. 'n Model is ontwikkel deur die gebruik van simulasiesagteware. Die model word dan geverifieer en bekragtig voordat 'n gedetailleerde bottelnekanalise gedoen word. 'n Operasionele strategie word vervolgens voorgestel vir optimale bottelnekbestuur. Hoewel die artikel fokus op die verbetering van motormonteersisteme wat in lotgroottes bedryf word, kan die metode ook toegepas word op 'n enkelmodel hand- en outomatiese produksielyne.

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/content/indeng/24/2/EJC144209
2013-08-01
2016-12-09
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