Modelling and Production Configuration Optimization for an Assembly Shop

Abstract

Flexible production is able to respond to a changing production system. To efficiently optimize a changed production layout and configuration, a modelling and optimization method based on discrete event simulation (DES) was proposed. A mathematical optimization model of the workshop layout was formulated and solved using a genetic algorithm (GA). In addition, a general modelling method for workshop logistics processes using DES was proposed to efficiently develop a simulation model of the complex production processes. Moreover, the simulation model of the entire production process was constructed using the Plant Simulation software package, and more production factors were considered and optimized. After the optimization process, the logistics volume decreased by 63.5 %, and the throughput increased by 42.0 %. Additionally, the production process was optimized, and the optimal equipment allocation, worker allocation, buffer allocation, and logistics vehicle allocation were determined. Our work can provide decision guidance and simulation validation for workshop planning.

A Simulation-Based Optimization Methodology for Facility Layout Design in Manufacturing

“…They state that the inclusion of logistics and reconfiguration in their approach would require the development of a more powerful algorithm. Yang et al [24] propose a modelling method and production configuration optimization for an assembly shop based on discrete event simulation (DES) and GAs. Optimization can, therefore, be a robust complement to simulation when the systems to be analyzed are large and complex [25].…”

“…In summary, the combination of simulation and optimization and especially the use of DES in this kind of complex manufacturing systems, can support the FLD decision process better than traditional methods if the system is complex and if simulation expertise and tools are available in the organization. DES can provide comprehensive, efficient, and accurate guidance for FLD [24]. Mathematical modeling approaches in manufacturing applications can be a good approach if resources with the required level of competence are available, and if the size and complexity of the layout design are between some boundaries.…”

Simulation and Evaluation of Production Factors in Manufacturing of Fireplaces

“…Production system availability is an important issue, especially when we take into consideration also failure analysis and dependability of the main production system components. To improve system availability is possible also by flexible changing the production configuration, as showed in [13]. Yang et al apply a genetic algorithm for efficient optimization by changing the production configuration -workers, machines, buffers, and transporters allocations.…”

“…Yang et al apply a genetic algorithm for efficient optimization by changing the production configuration -workers, machines, buffers, and transporters allocations. The Discrete event simulation (DES) modelling method for improving factory logistics processes, using the Plant Simulation software package, was presented in studies [13] and [14]. Aggregate modelling and simulation concepts are presented in [15] and [16].…”

Modern Optimization and Simulation Methods in Managerial and Business Economics: A Review

“…Optimization for configuring simulation: Here, the simulation is employed to evaluate the feasibility of a solution found by the optimization (Yang et al 2019).…”