Using simulation in layout verification of solar module assembly workshop

2018 ◽  
Vol 09 (02) ◽  
pp. 1850017
Author(s):  
Zhongqing Liao ◽  
Ming Cong ◽  
Dong Liu ◽  
Fanjie Meng
Keyword(s):  
Production Process ◽  
Material Flow ◽  
Optimal Number ◽  
Solar Module ◽  
Reusable Component ◽  
Work In Process ◽  
3D Simulation Model ◽  
Systematic Layout Planning ◽  
Short Time ◽  
Component Models

Facility layout problem (FLP) contemplates the optimization of space utilization, costs, and material flow. Commercial simulation softwares are commonly used to validate layouts by simulating the real world material flow and production process. To validate a layout scenario of a solar module assembly workshop, a 3D simulation model is presented which was designed on VisualComponents software. To begin with, we introduce the layout characteristics and use the systematic layout planning (SLP) method to design the block layout of workshop. Then, we built components library which contains all the facilities needed in the production line, specifically conveyors, processing equipments, robots, buffers. Finally, we have established a simulation layout model using the components in the customized library according to the block layout, and configured the components which were allocated in the layout by setting the parameters and building the connection between components via signal. To improve the performance of the workshop, we have found the best work-in-process (WIP) value for the workshop and the optimal number of workers. Additionally, the layout model was used to test collision and reachability. It demonstrated the production process in a realistic simulation environment which helped in the sales process as well. The reusable component models we have built make it easy to build a layout within a short time and validate the effectiveness of the layout scenarios for any other projects.

scholarly journals Shipyard Production Processes Re-Design Methodology Based on Expert Approach and Simulation Modeling

2016 ◽  
Vol 51 (1) ◽  
pp. 25-41
Author(s):  
Tin Matulja ◽  
Marko Hadjina ◽  
Damir Kolić
Keyword(s):  
Production Process ◽  
Process Design ◽  
Simulation Modeling ◽  
Material Flow ◽  
Analytic Hierarchy ◽  
Layout Planning ◽  
Design Alternatives ◽  
Systematic Layout Planning ◽  
Viable Approach ◽  
Optimal Material

The authors propose a synergy of expert approach methods through the Systematic layout planning (SLP) and Analytic Hierarchy Process (AHP) as tools for the shipyard production process design towards an optimal material flow, in combination with Simulation modeling (SM). Most production process designs are based on the conventional methodology of comparison initiating with benchmarking. Such approach can be misleading. For more reliable and efficient results, the approach suggested by the authors uses a combination of the mentioned three methods within the frame of an expert approach. Firstly, the Systematic layout planning is used for generating a larger number of suboptimal shipyard production process design alternatives. Then, these alternatives are analyzed through an objective decision making tool to reach an optimal material flow alternative. Further, such optimal alternative is tested and evaluated by Simulation modeling (SM). Finally, the presented methodology is confirmed on a case study as a viable approach to an efficient and reliable shipyard production process design.

scholarly journals Methodology for Searching Representative Elements

2019 ◽  
Vol 9 (17) ◽  
pp. 3482 ◽  
Author(s):  
Jure Murovec ◽  
Janez Kušar ◽  
Tomaž Berlec
Keyword(s):  
Production Process ◽  
Material Flow ◽  
Global Market ◽  
Huge Number ◽  
Industrial Environment ◽  
Loading Function ◽  
Permanent Improvement ◽  
Flow Through ◽  
Abc Analysis ◽  
Short Time

Companies have to assure their share on the global market, meet customer demands and produce customer-tailored products. With time and production line updates, the layout becomes non-optimal and product diversity only increases this problem. To stay competitive, they need to increase their productivity and eliminate waste. Due to a variety of products consisting of similar components and variants thereof, a huge number of various elements are encountered in a production process, the material flow of which is hardly manageable. Although the elements differ from each other, their representative elements can be defined. This paper will illustrate a methodology for searching representative elements (MIRE), which is a combination of the known Pareto’s analysis (also known as ABC analysis or 20/80 rule) and a calculation of a loading function, that can be based on any element feature. Results of using the MIRE methodology in a case from an industrial environment have shown that the analysis can be carried out within a very short time and this provides for permanent analysis, optimisation and, consequently, permanent improvement in the material flow through a production process. The methodology is most suitable for smaller companies as it enables rapid analysis, especially in cases when there is no pre-recorded material flow.

scholarly journals PELATIHAN MATERIAL FLOW COST ACCOUNTING (MFCA) BAGI PARA UMKM DI DKI JAKARTA

2022 ◽  
Vol 3 (2) ◽  
pp. 197-202
Author(s):  
Virna Sulfitri ◽  
Henik Hari Astuti ◽  
Budi Santosa
Keyword(s):  
Production Process ◽  
Community Service ◽  
Material Flow ◽  
Cost Accounting ◽  
Face To Face ◽  
The Public ◽  
Direct Contribution ◽  
Effectiveness And Efficiency

Community Service is one part of the direct contribution from academics, in this case the Faculty of Economics and Business, Trisakti University to the community. On this occasion the Trisakti University FEB team had the opportunity to provide training on Material Flow Cost Accounting (MFCA) for MSMEs. This training is considered important considering that the understanding of MSME actors in terms of the flow cost of material is still very minimal, so that in the implementation of their business there are still very few who apply it in the production process. This training aims to educate MSME actors in terms of flow cost accounting for the use of their production materials, MSMEs can sort out the types and types of materials to be used so as to increase the effectiveness and efficiency of production to increase sales and business profits. PKM training will be carried out using an online method considering the conditions of the COVID-19 pandemic, which until now has not allowed face-to-face/off-line training. The output of this PKM will be published to the public so that it can provide wider benefits.

scholarly journals THE UPGRADED ROLE OF THE VALUE STREAM DESIGN FOR REDESIGNING THE FACTORY LAYOUT

2020 ◽  
Vol Vol. 36 (No. 2) ◽  
pp. 49-57
Author(s):  
István Vajna ◽  
Anita Tangl
Keyword(s):  
Material Flow ◽  
Layout Design ◽  
Simulation Software ◽  
Shop Floor ◽  
Value Stream ◽  
Work In Process ◽  
Production Area ◽  
Production Areas ◽  
Milk Run ◽  
Factory Layout

The case study shows the re-optimization of an initial new factory layout design with Value Stream Design (VSD). The VSD is a quantitative method and its’ final goal is to make a waste free optimized material flow. The primary goal of arrangement is to reduce transportation distances and frequencies, optimize human load. Initially the whole factory shop floor layout design was already made in push concept. The plans were made by production management, logistics, engineering department at the headquarter of the multinational automotive company with based on VDI2870 holistic concept linking strategy on tactics and operation. On the layout (v1.) the hundreds of machines were placed and arranged by CAD (Computer Design) engineers to fit the space. The factory building has 15,000 m2 with empty shop floor waiting for the final decisions for equipment. The factory production area was shared into six main production areas (P1-P6), which correlates with their product complexity of the product families. Each production area output can be finished product (FP) or semi-finished product (SFP) for the next production areas. To validate the whole factory layout it was necessary to involve lean experts that identified disadvantages and constraints. Without lean implementation the company’s transportation waste would be 49% more per year. The Value Stream Design importance nowadays is upgrading to a higher level, when the whole global business is changed, the labor force fluctuates, and the cost and delivery time reduction plays a vital role in the company’s profit and future. The research shows that if the decision taking is based on real data and facts the controlling and management can do its best in time. Using VSD and re-evaluating the transportation routes, frequency and costs is the first step to define a smooth, low cost, material flow (v2.). This development ensured the company to drive from push to pull production through mixed production system. Originally, the production flow was clockwise orientation. It was changed step by step to mixed production by eliminating work in process storages, implementing FIFO lanes, Milk Run, and Kanban. The total annual transportation distances were reduced from 4,905,000 m between the rump-up and serial production period. The warehouse storage size was reduced to 50% and implementation cost from €75,000 to €32,500. By eliminating work in process storages along production lines it was possible to open a new two way transportation road that also will serve the AGV’s operations in industry 4.0 projects. Due to decreased lead time the logistic labor productivity increased by 45%. Besides taking measurements for the VSD it was used Value Stream Mapping as a lean tool and an own designed VSD evaluation and a simulation software. The VSD team’s cooperative actions reduced the evaluation and validation time with 65% then it was initially planned. The implementations were evaluated from the rump-up phase to the first serial productions and the results were confirmed by controlling and management

scholarly journals Speculation, segregation and (absence of) conflicts: In the production of the urban space of Palmas / TO

2017 ◽  
Vol 2 (3) ◽  
Author(s):  
Ana Carla de Lira Bottura
Keyword(s):  
Production Process ◽  
Urban Space ◽  
Western World ◽  
New Town ◽  
Doctoral Research ◽  
The Social ◽  
Object Of Study ◽  
Space Production ◽  
Short Time ◽  
The City

This article introduces partial discussions from a doctoral research in progress that has as object of study the tendency to paci cation and concealment of con icts veri ed in the production process of contemporary urban space - particularly in the most recent Brazil- ian cities - as well as its strategies and mechanisms of control. As a eld of study, it is proposed the city of Palmas, capital of Tocantins, last planned capital of the twentieth century, founded on May 20, 1989, a year that symbolizes the opening of the Western world to the neoliberal economic policy. Based on the observation of the absence of signi cant movements of resistance to the urban space production process at Palmas and interpreting it as a re ection of pacifying tendency of consensus and appeasement / masking of con icts as a feature of neoliberal city, we propose the hypothesis of physical and territorial con guration of the city as a laboratory of the neoliberal model of urban management, in which socio-spa- tial dynamics gradually developed in other contemporary cities through processes historically constructed, get explicit and take place, immediately or in a very short time. Through a historical ap- proach to the context of its creation and occupation, we propose an urban space production reading based on the recognition of char- acteristics relating to its conditions of New Town and neoliberal city as well as the incipient action of the social movements dedicated to the struggles for housing as social agents in this process. 

Analysis and Evaluation of Differences Dimensional Products of Production System

2014 ◽  
Vol 611 ◽  
pp. 339-345 ◽  
Author(s):  
Pavol Božek ◽  
Peter Pokorný
Keyword(s):  
Production Process ◽  
Production System ◽  
Manufacturing Process ◽  
Material Flow ◽  
Raw Materials ◽  
Information Flows ◽  
Production Logistics ◽  
Analysis And Evaluation ◽  
Course Material ◽  
Business Functions

Logistics is primarily to address issues with whose functional, organizational, personnel and material means can be improved and optimize the entire course material flow businesses, which shall logistics integration business functions. Production logistics means a sum of logistical tasks and measures for preparation and execution of the production process. Includes all activities associated with material and information flows of raw materials, auxiliary and production materials from the warehouse to the production of raw materials and semi-finished goods from the warehouse and purchased parts through the various steps of the manufacturing process including all buffer stores, through the installation of the finished goods warehouse.

scholarly journals Reusable Component Model Development Approach for Parallel and Distributed Simulation

2014 ◽  
Vol 2014 ◽  
pp. 1-12 ◽  
Author(s):  
Feng Zhu ◽  
Yiping Yao ◽  
Huilong Chen ◽  
Feng Yao
Keyword(s):  
Distributed Simulation ◽  
Model Development ◽  
Component Model ◽  
Model Framework ◽  
Domain Experts ◽  
Reusable Component ◽  
Parallel And Distributed Simulation ◽  
Development Approach ◽  
Two Phases ◽  
Component Models

Model reuse is a key issue to be resolved in parallel and distributed simulation at present. However, component models built by different domain experts usually have diversiform interfaces, couple tightly, and bind with simulation platforms closely. As a result, they are difficult to be reused across different simulation platforms and applications. To address the problem, this paper first proposed a reusable component model framework. Based on this framework, then our reusable model development approach is elaborated, which contains two phases: (1) domain experts create simulation computational modules observing three principles to achieve their independence; (2) model developer encapsulates these simulation computational modules with six standard service interfaces to improve their reusability. The case study of a radar model indicates that the model developed using our approach has good reusability and it is easy to be used in different simulation platforms and applications.

Systematic Layout Planning to Assist Plant Layout: Case Study Pulley Factory

2011 ◽  
Vol 110-116 ◽  
pp. 3952-3956 ◽  
Author(s):  
Anucha Watanapa ◽  
Wisitsree Wiyaratn
Keyword(s):  
Optimum Design ◽  
Surface Finish ◽  
Material Flow ◽  
Activity Relationship ◽  
Plant Layout ◽  
Layout Planning ◽  
Space Requirement ◽  
Operation Process ◽  
Systematic Layout Planning

In this study, the application of a systematic plant layout planning (SLP) to assist the optimum design of process areas and locations is proposed. The number of machines and space requirement in pulley factory is determined. The operation process chart, flow of material and activity relationship chart have been investigated. The relationships between machines, operation sections and material flow are used to determine the suitable position of each activity. The SLP method has been employed to design the two alternative plant layouts and compare the performances between new layout and present layout in term of material flow. The new plant layout is modified by moving a disassembly and surface finish that significantly decrease the distance of material flow, so it is effective increasing production.

Layout performance indicators and systematic planning

2015 ◽  
Vol 117 (8) ◽  
pp. 2098-2111 ◽  
Author(s):  
Milena Flessas ◽  
Vinicius Rizzardi ◽  
Guilherme Luz Tortorella ◽  
Diego Fettermann ◽  
Giuliano Almeida Marodin
Keyword(s):  
Employee Performance ◽  
Food Service ◽  
Working Environment ◽  
Layout Planning ◽  
Content Type ◽  
Work In Process ◽  
Systematic Layout Planning ◽  
Productive Area ◽  
Production Area ◽  
Systematic Planning

Purpose – The purpose of this paper is to plan the layout of the production area of an industrial kitchen of a theme restaurant through the application of the systematic layout planning (SLP) methodology and the establishment of layout indicators with a specific application in the restaurant business. Design/methodology/approach – The authors applied the SLP methodology in the industrial kitchen of a theme restaurant in order to plan and develop layout alternatives. Such layout alternatives were then evaluated according to a set of specific indicators consolidated based on a literature review. Finally, a multi-criteria decision-making tool was used to support the selection of the best layout alternative and suggest to the case study area. Findings – The main results could be highlighted as: first, an area, previously unexplored, of approximately 5.40 m² ended up being used as a productive area for the operations; second, 40 percent reduction in work-in-process by removing the refrigerators of groceries and the freezer from the production area; third, indirect indicators, such as customer satisfaction and the employee’s workplace environment, have increased their performance, since customers were better served and working environment became more conducive to a good employee performance. Originality/value – Most research in layout planning is typically developed in productive industrial areas, and this paper contributes to the understanding the differences of implementing SLP methodology in a food service business, such as restaurant, and proposes the utilization of specific layout indicators.

scholarly journals Aplikasi Ergonomi untuk Meningkatkan Produktivitas Pengrajin Kayu Bekas (Drifwoods) di Kabupaten Badung, Bali

DEDIKASI ◽  
2019 ◽  
Vol 21 (1) ◽  
Author(s):  
I Gede Nyoman Suta Waisnawa ◽  
I Made Sudana ◽  
Ida Bagus Swaputra
Keyword(s):  
Production Process ◽  
Work Environment ◽  
Material Flow ◽  
Production Capacity ◽  
Working Environment ◽  
Participatory Ergonomics ◽  
Business Partners ◽  
The Impact ◽  
Safe Working ◽  
Ergonomic Intervention

The results of the implementation of ergonomics in deco and shop camps were specifically focused onimproving work facilities, workplaces, layouts, work procedures, and work environment, increasing workers'comfort in conducting production activities, and utilizing space so that the production process becomes safe andflexible. Outputs that have been achieved included (1) workstations arranged in an efficient material flow layoutsupported by adequate work tools so it can optimize the achievement of production targets, (2) improvement of theprocess and procedures for completing work, (3) improvement and savings in the use of materials, machinery/tools,and humans, (4) utilization of humans’ efforts, (5) improving workspace arrangements that can provide acomfortable and safe working environment. The implementation of participatory ergonomics production capacitycan reach 456 pieces/year and shop production as many as 24 pieces/year, for example; tiger, bear, eagle, cow headetc. After the ergonomic intervention, the production capacity increased to 52 pieces/year. The impact of thisprogram was an increase in production capacity of Ari deco craftsmen (67.5%) and Kubu shop craftsmen (46.15%),while business partners' turnover was around 69.9%.

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