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

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Table 4.2 First Time Pass Rate of Station 5b, 6, 8, 10 and 11 Station 5b 6 8 10 11 First Time Pass Rate 98~99% 99.2% 99.2% 99.2% 99.2% Based on the result analyzed by Haldex, the bottlenecks of the whole assembly line system are station 2 in the preassembly line and station 8 in the main assembly line. For these two parts, extra “Downtime” blocks are added. Those blocks have set TTF (or TBF, Time between Failures) i.e. the time to fail mentioned in data analysis section and TTR (Time to Repair) value to shut down and restart the system as time flows by. In the end of the model, a “Plotter” is there, plotting the output rate corresponding to the two “shutdown”. It is easier to detect that where the simulation is stuck by checking the plot. Based on the simplified model, some further modifications are added in the model due to different requirements of the solution and the changing situations. Detailed reasons and approaches are specifically presented in the following section. 4.2 Simulation and analysis After the modeling of current situation is finished, simulation and analysis are taking place. First of all, there is a Transient State before the system run into a steady state. This situation only happens at the beginning of the production since the flow of material is from the head of the assembly line. Besides, all the constraints are set in disciplinary values, which will not cause big fluctuations during the steady state. For example, the interrupts caused by failures will only make the production pause in a disciplinary time interval all through the assembly period. Figure 4.2 below can describe the working state of the assembly line. In the figure, x could represent the production rate and t could represent time or certain stops, such the number of outputs. Figure 4.2 Transient State and Steady State (Semere, 2007) Simulate the current line for a period of time, until 50 items are outputted. Table 4.3 listed the time when each item is finished and the calculated production rate, output numbers divided by the time. 22
Table 4.3 Output Date Come From the Simulation Output Time (sec.) Production Output Time (sec.) Production no. rate (pcs/sec) no. rate (pcs/sec) 0 0 0 26 3318.292037 0.007835356 1 466.6531527 0.002142919 27 3384.292037 0.007978035 2 526.6531527 0.003797566 28 3450.292037 0.008115255 3 598.6531527 0.005011249 29 3516.292037 0.008247324 4 658.6531527 0.006072999 30 3582.292037 0.008374527 5 718.6531527 0.006957459 31 3648.292037 0.008497127 6 778.6531527 0.007705613 32 3714.292037 0.00861537 7 939.2833014 0.007452491 33 3780.292037 0.008729484 8 1025.283301 0.007802721 34 3846.292037 0.008839682 9 1085.283301 0.008292766 35 3932.292037 0.008900661 10 1145.283301 0.008731464 36 3992.292037 0.009017376 11 1223.283301 0.008992193 37 4052.292037 0.009130635 12 1283.283301 0.009351014 38 4112.292037 0.009240589 13 1841.517721 0.007059394 39 4368.044535 0.00892848 14 1901.517721 0.00736254 40 4610.691915 0.008675487 15 1961.517721 0.00764714 41 4670.691915 0.008778143 16 2039.517721 0.007844992 42 4730.691915 0.008878194 17 2099.517721 0.008097098 43 4808.691915 0.008942141 18 2159.517721 0.008335194 44 4868.691915 0.009037335 19 2237.517721 0.008491553 45 5393.005303 0.008344142 20 2303.517721 0.008682373 46 5619.69396 0.008185499 21 2363.517721 0.008885061 47 5679.69396 0.008275094 22 2423.517721 0.009077714 48 5952.749388 0.008063501 23 2873.895077 0.008003076 49 6038.749388 0.008114263 24 2959.895077 0.008108396 50 6098.749388 0.008198402 25 3252.292037 0.007686887 Figure 4.3 Production Rate of the Assembly Line 23
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 and 28: Table 3.6 Values of Parameters of T
Page 29: line. In order to simplify the mode
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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