Improvement of Material Flow in the Production and Supply Chain of ...

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Chapter 3 Data analysis of production line Material flow is through all over the production line. From very begin the raw and processed materials to each step of process even to finished product. So material flow analysis is the base of optimize production line. An operator-paced line flow production system produces products on equipment arranged in a line layout. The material flow in an operator-paced line flow production system is regular mostly (John Miltenburg, 2005). In this chapter, data collected from factory will be analyzed by Microsoft Excel and SPSS (Statistical Program for Social Science). 3.1 Introduce of data analysis Data gathered is the first step in the research. According to the requirement in setting up production line model, the data around the production line are gathered from the workshop during the early period of research. The scope of the data includes processing time, maximum queue length of each step, percentage of scraps, production cycle time, stop time and so on. Time to Failure (TTF) (or Time between Failures (TBF)) and Time to Repair (TTR) are acquired through statistical analysis in this chapter. The whole production of ADBs includes several sub-lines, such as main production line, sub-production line, preassembly line, main assembly line and so on. In this study, analysis is emphasized in the key issues. The research is taken out on the ADB (Air Disc Brake) assembly line, which is comprised of a preassembly line (assemble the magnetism part) and the main assembly line (final assembly line). Meanwhile, variety of the ADB products is ignored to simplify the analysis and simulation. Instead, the company provides integrative data on assembly line. The preassembly contains four stations and the main line has ten stations. A general layout sketch of the whole assembly line of ADB is shown in Figure 3.1. The blue rectangles are the preassembly line stations and the gray ones are the final assembly line stations. The yellow triangles mean the buffers of material, which are used to store the components, will be used in the corresponding stations. The preassembly line joins the main line at station 5 after 10
processing in station 5b. In the real production, preassembly line and final assembly line operate independently. At the end of preassembly line there is an area used to deposit the first finished production i.e. the magnetism part of Air Disc Brake. In this sketch in order to show the relationship of the two assembly lines, a connection line is used between station 4 of the preassembly and station 5b of the main line instead of the deposited area. Among the stations PA2, MA4, MA7 and MA8 are auto processing and worked by robots. Figure 3.1 Simplified Assembly Line Among the data of assembly line gathered from the workshop, processing time and maximum queue length of each step can be used in “Extend v6” directly when set up simulation model. While the data of TTF and TTR are statistic data, which has to analyze before used in building model. In this paper, the data will be analyzed in Microsoft Excel and SPSS. The two groups of data for different stations will be analyzed separately. First data for station 2 in preassembly line will be analyzed and then the final assembly line data for station 8. The analysis methods and threads are similar. 11
Page 1 and 2: ROYAL INSTITUTE OF TECHNOLOGY Impro
Page 3 and 4: Needs to be pointed out is that in
Page 5 and 6: TABLE OF CONTENTS ABSTRACT.........
Page 7 and 8: List of Tables Table 3.1 Descriptiv
Page 9 and 10: CHAPTER 1 INTRODUCTION OF THE RESEA
Page 11 and 12: 1.2 Present problems Haldex faces i
Page 13 and 14: CHAPTER 2 RESEARCH THEORY AND METHO
Page 15 and 16: mindset simply does not accurately
Page 17: the customers. Both of them are pri
Page 21 and 22: After deleting the un-normal data i
Page 23 and 24: data of preassembly line accords wi
Page 25 and 26: Standard Deviation 68.49 Standard D
Page 27 and 28: Table 3.6 Values of Parameters of T
Page 29 and 30: line. In order to simplify the mode
Page 31 and 32: Table 4.3 Output Date Come From the
Page 33 and 34: Table 4.5 Current Production Volume
Page 35 and 36: Table 4.7 listed the simulation res
Page 37 and 38: 4.3.3 Increasing the operation time
Page 39 and 40: ottlenecks. Obviously, from the poi
Page 41 and 42: the first one. For the third soluti
Page 43: and unforeseen events by keeping sa
Page 46 and 47: separately and the supply chain emp
Page 48 and 49: 5.2.1 Current distribution of suppl
Page 50 and 51: Table 5.2* Delivery Information of
Page 52 and 53: ecause this only gets from experien
Page 54 and 55: 5.3.2 Inventory and suppliers’ se
Page 56 and 57: Table 5.3 Integrative Estimation of
Page 58 and 59: CHAPTER 6 INVENTORY REDUCTION AND D
Page 60 and 61: How to get the best value from a su
Page 62 and 63: calculation, 420 pallets can be suc
Page 64 and 65: each day. The maximum load of one t
Page 66 and 67: and can also overworking during wee
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CHAPTER 7 CONCLUSION AND FUTURE WOR
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Reference Books and papers • Ahma
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y Chapman&Hall. • Vickery, Shawne
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Appendix A Table 1 TTF & TTR Data o
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Table 5.1 Suppliers & Suppliers’
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Appendix B Figure 1 Assembly line M
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Figure 3 Current Assembly Line Mode
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Figure 5 Assembly Line Model in Sol
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