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Modelling & Simulation of Flexible Manufacturing System

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Vivek Veluri

on 25 March 2015

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Transcript of Modelling & Simulation of Flexible Manufacturing System

Replication length and hours per day are defined.

Number of replications is calculated to increase confidence using

where, n*= number of replications
h*= required half width
n = current number of replications
h = current half width Limitations

No unique solution.

Simulation results are probable solutions.

Future Work

Combining both cells into a single cell.

Alternative models could be designed. Future work Lean practice.

Improved overall performance.

Capacity questions answered.

Make right changes at right time.

Supplies a scientific basis for decision making. Conclusion Decreased idle costs.

Increased annual turnover. Increased operator utilization.

Optimal worker allocation. An iterative process.

Proposed changes are made to the system.

Lean manufacturing?

eliminate wastes,

decrease WIP and inventory levels,

minimise cycle time,

reduce costs. Experimental Modelling Operator utilization shown below illustrates numerous inefficiencies. Production does not meet demand.

Of the total running costs, idle costs are high.

Low annual turnover.

High queue times at work stations.

Bottle necks.

High cycle times.

Unparallel assembly feed. Data Analysis Cell Design Garbage in = Garbage out.

Credible formulation of the problem is vital.

Time consuming and delicate.

Usage of raw data for input scheduling.

Modules from different template panels are used. Preliminary Modelling Graphical Interface First released in 1993 by Rockwell Automation.

Creates animated simulation models.

Uses graphical units called ‘modules’.

Built in animation tool that mimics a real system.

Detailed results can be obtained for analysis. ARENA What is Simulation? Simulation A flexible manufacturing system

Highly inefficient,

Variability in demand,

System failures,

Labour variations and

Order complexities.

Is simulation the answer to optimize workflow? Overview Vivek Bhargav Veluri
MSc Manufacturing Management
University of Bradford Modeling & Simulation
of a
Flexible Manufacturing System Process analyser.

Production meets demand.

Reduced cycle time. Comparative Analysis Attributes for animation are defined. Animation Run Setup Problem Definition

Problem Formulation

Conceptual Model

Programmed Model

Preliminary Analysis

Experimental Model

Comparative Analysis

Simulation Results Life Cycle of Simulation A real time flexible manufacturing system

Assembly process:

Delays in the system, high WIP, variety in processes and demand, labour allocation, financial turnover.

What should the capacity be to meet demand? Problem Definition a process
designing a model of a real system
conducting experiments
to understand its behaviour
evaluating various strategies
System Conclusion Preliminary
Results Experimental
Modelling Introduction Unit Assembly Section Shell Assembly Final Assembly
(Section shells + Units) Start Flexible Manufacturing System? THANK YOU
Full transcript