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

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CHAPTER 4 MODELING AND ANALYSIS OF PRODUCTION LINE 4.1 Modeling Figure 4.1 Simplified Assembly Line Model Depend on the sketch layout of Figure 3.1 production line model is set up by software Extend v6 after data analysis. The simplified assembly line in the beginning is detailed by adding variances in critical stations and bottlenecks. Figure 4.1 is a copy of the simplified assembly line model setting in Extend v6. There are two stocks at the beginning of the flow, one for the main assembly line and the other for the preassembly 20
line. In order to simplify the model and bring the keystones to the front, the two lines are joined together and working simultaneously. The detail situation about the preassembly line and main assembly line has described in chapter three. During the process of setting up model, there is a problem when associating the preassembly line to the main assembly line. As shown in Figure 3.1, there are five stations before insert the preassembly line at station 5b. According to the data of process time shown in Table 4.1 below, from the beginning to output the first product, the working time of first five stations in main assembly line is 105s, which is shorter than the working time of preassembly line that is 179s. As a result, for the early period preassembly line is behind the main assembly line. So a buffer with the products of the preassembly line is needed. By setting another “Stock” block between station 5b and station 5, the two assembly lines join together at station 5 of the main production line to smooth the simulation. This solution is not discrete form the reality since in the virtual assembly process, there is a small holding area used to store the magnetism parts from the preassembly line, which can satisfied the requirement of main assembly line. The “Stock” block in the model has the same function as the holding area. There are several reasons lead to the necessary of a holding area; one of them is that the cycle time of the main assembly is longer than the cycle time of the preassembly line, which can be confirmed by the data shown in Table 4.1. Calculated the delayed time, the model can work smoothly as long as more than three items are held in the stock. Table 4.1* Working Parameters of Each Station Station/Main TID Queue Station/Pre. TID Queue Capacity Capacity 1&2 1 3 2 4 3 5b 5 6 4 7 *Because of the different 8 configurations, TID of station 10 in 9 10 11 main assembly line is variation. 7/30 of the products cost 55s at this station and the rests cost 35s. In the model, each buffer before the stations is to simulate the length of the queue. All the stations indicate the actual working times in the assembly line. The detailed information of processing time (TID) and queue length for each station are listed in Table 4.1 above. Generally speaking, scraps occur in station 5b, 6, 8, 10 and 11 of main assembly line. Statistical analysis work focus on these five stations. First time pass rates of the five stations are shown in Table 4.2 separately. “Select DE Output” blocks are added after these stations to simulate the pass rates. 21
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 and 18: the customers. Both of them are pri
Page 19 and 20: processing in station 5b. In the re
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: Table 3.6 Values of Parameters of T
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
Page 68 and 69: CHAPTER 7 CONCLUSION AND FUTURE WOR
Page 70 and 71: Reference Books and papers • Ahma
Page 72 and 73: y Chapman&Hall. • Vickery, Shawne
Page 74 and 75: Appendix A Table 1 TTF & TTR Data o
Page 76 and 77: Table 5.1 Suppliers & Suppliers’
Page 78 and 79:
Appendix B Figure 1 Assembly line M
Page 80 and 81:
Figure 3 Current Assembly Line Mode
Page 82 and 83:
Figure 5 Assembly Line Model in Sol
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