Design and simulation of assembly line feeding systems in the automotive sector using supermarket, kanbans and tow trains: a general framework

Abstract

A growing number of manufacturers are adopting the so-called supermarket strategy to supply components to the production system. Supermarkets are decentralized storage areas used as intermediate warehouses for parts required by the production system (typically assembly lines). Such a feeding system is widely used in the automotive industry where assembly stations in multiple mixed-model assembly lines are usually refilled by means of a systematic part replenishment driven by Kanban systems, adopting small trucking vehicles towing some wagons (tow trains). The aim of this paper is to provide a simple but robust framework in order to design the supermarket/feeding system dedicated to complex multiple mixed-model assembly lines. This framework proposes an integrated approach both for long-term (static analytical model) and short-term (dynamic simulation) problems dealing with Kanban and Supermarket systems dedicated to assembly lines, and the tow train fleet sizing and management. This proposed methodology is applied to a case study derived from the Italian automotive industry, and the results highlight the high interrelation between the long and the short term variables that can be evaluated only by an integrated approach that considers both static and dynamic aspects of the problem. The results of this study are then presented and widely discussed

Efficient material flow in mixed model assembly lines

“…Early loading must be controlled in a good way to minimize inventory holding costs. In a study by (Faccio et al 2013), the fleet size (which is part of routing problem) and kanban number were investigated in static and dynamic steps of analysis. However, that study assumes using one supermarket feeding a group of assembly lines.…”

Dynamic material flow control in mixed model assembly lines

“…Before that, they presented the distribution of demand for bins assuming that the demand is always one or two bins for each workstation during the train cycle. A study by Faccio, Gamberi, Persona, Regattieri, and Sgarbossa (2013b) used simulation to analyze the system. In another study by Faccio, Gamberi, and Persona (2013a), a cost model has been proposed using analytical approach.…”

Production logistics design and development support through simulation-based optimization (WIP)

“…However, their approach is strictly related to Assembly to Order/Manufacturing to Order and there is not much emphasis or description of the simulation and optimization parts. Another complete article but more focused in towtrains sizing, [17], presents the line feeding problem and models the logistics between a central supermarket area and the production lines of an italian automotive company.…”