Job shop production system is characterized by manufacturing feature with low volume and high variety of product designs. It is a process with high flexibility which produces a wide variety of products in low quantities and high divergence. Generally, a job shop production line follows sequence of orders with specific process flow for each particular job. In each work station, special skills of workers are required to perform explicit tasks. Due to these distinctive process characteristics, effective production planning is crucial for job shop manufacturing process. Ineffective production planning may cause several types of waste in production line. This study proposed simulation modeling for job shop production process in machine parts manufacturing. Simulation models present the great benefits to assist in performance improving, problems solving, including a great help in decision making. The experimental results of the study showed that group technology, plant layout, job enlargement, and capacity expansion accomplished the definite value in reducing operating cost and increasing average worker utilization, thereby increasing the efficiency of the system.
Due to the higher competition in automobile industry, automotive part manufacturers who supply parts have also been challenged to improve the quality of their products to meet customers' requirements. Quality of parts or products could be controlled and improved since the stage of production process design. Efficient production process design could reduce work in process (WIP), wastes, reworks, errors, and failures, which could reduce system cost and increase quality of final products. However, production process design for the process which implements automatic systems is sophisticate due to the complication of the equipment itself and the synchronization requirement. This study presents the use of computer simulations to design an automotive part production process. Two objectives are proposed. The first one is to introduce three dimension robot (3D CAD) simulation for robotic work stations designed to meet the desired cycle time with minimum chance of robot collision and minimum number of robots in the system. The second one is to propose plant simulation for production planning design in order to produce product which could meet the desired capacity and customer needs with minimum number of workers.
The purpose of this study was to increase the quality of product by focusing on the machine efficiency improvement. The principle of the reliability centered maintenance (RCM) was applied to increase the machine reliability. The objective was to create preventive maintenance plan under reliability centered maintenance method and to reduce defects. The study target was set to reduce the Lead PPM for a test machine by simulating the proposed preventive maintenance plan. The simulation optimization approach based on evolutionary algorithms was employed for the preventive maintenance technique selection process to select the PM interval that gave the best total cost and Lead PPM values. The research methodology includes procedures such as following the priority of critical components in test machine, analyzing the damage and risk level by using Failure Mode and Effects Analysis (FMEA), calculating the suitable replacement period through reliability estimation, and optimizing the preventive maintenance plan. From the result of the study it is shown that the Lead PPM of test machine can be reduced. The cost of preventive maintenance, cost of good product, and cost of lost product were decreased.
Thai jewelry is the world’s leading jewelry which has gained high reputation and recognition from customers worldwide. In the past decade, jewelry have become one of the top ten export product of Thailand with the current export value of around 58,000 million baht per year which is 3.4 percent of all Thailand export products. Due to the high competition in the world market, however, Thai jewelry manufacturers needs to continue to improve their product quality as well as process efficiency in order to gain more market share. Currently, computer-aided tools have become more powerful tool in jewelry production management. They have been used to design production process, plant and workstation layout, production planning, worker’s scheduling, and other decisive decision making in both high management and shop floor levels. This research demonstrates a case study of plant simulation application for jewelry production process improvement. The objective is to reduce bottlenecks and increase productivity in wax pattern and casting processes using line balancing. Various scenarios have been proposed in order to support different level of desired output rate due to the increase of demand. The results of line balancing and simulation models reduce bottlenecks. Hence, productivity is increased. The desired throughput rates are achieved with the minimum number of workers and machine in the system.
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