Evaluating the Effect of Main Factors in Manufacturing Production Line Based on Simulation Experiment

2014 ◽  
Vol 606 ◽  
pp. 199-203 ◽  
Author(s):  
Milad Hatami ◽  
Seyed Mojib Zahraee ◽  
Alireza Khademi ◽  
A. Shahpanah ◽  
Jafri Mohd Rohani
Keyword(s):  
Production Line ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Failure Time ◽  
Service Rate ◽  
Manufacturing Companies ◽  
System Productivity ◽  
High Production Rate ◽  
Need To Evaluate ◽  
High Level

Productivity plays a significant role for most companies in order to measure the efficiency. In reality there is an essential need to evaluate the different factors which increasing productivity and achieving the high level of quality, high production rate , machine utilization. On the other hand, manufacturing companies are striving to sustain their competitiveness by improving productivity and quality of manufacturing industry. So it can be acquired by finding ways to deal with various industrial problems which have affected the productivity of manufacturing systems. This paper aims at applying statistical analysis and computer simulation to recognize and to weight the significance of different factors in the production line. Based on the final result the two factors which are B (Number of labor) and C (Failure time of lifter) have the most significant effect on the manufacturing system productivity. In order to achieve the maximum productivity the factors should be placed on the levels which are: A= -1, B=1, C=1 and D=1. This means that the service rate of mixer = UNIF (20, 40), number of labor=20, failure time of lifter =60 min and number of permil=5 respectively.

Comparison of Different Scenarios Using Computer Simulation to Improve the Manufacturing System Productivity: Case Study

2013 ◽  
Vol 845 ◽  
pp. 770-774 ◽  
Author(s):  
Seyed Mojib Zahraee ◽  
Milad Hatami ◽  
J.M. Rohani ◽  
H. Mihanzadeh ◽  
Mohammadreza Haghighi
Keyword(s):  
Computer Simulation ◽  
Production Line ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Manufacturing System ◽  
Waiting Times ◽  
Manufacturing Companies ◽  
System Productivity ◽  
High Resource

In the manufacturing industry, managers and engineers are seeking to find methods in order to eliminate the common problems in manufacturing systems such as bottlenecks and waiting times. This is because that all of these kinds of problems impose extra cost to the companies. In addition, manufacturing companies are striving to sustain their competitiveness by improving productivity, efficiency and quality of manufacturing industry for instance high throughput and high resource utilization. The paper concentrates on the application of computer simulation to analysis manufacturing system in order to improve the productivity. Therefore, this study introduces a color manufacturing line as a case study and the basic application of arena 13.9 software. The goal of this paper is to improve the productivity and efficiency of the production line by using computer simulation. To achieve this goal, first the basic model of the current situation of production line was simulated. Second, three different alternatives were simulated and modified to find the best scenario based on the maximum productivity and minimum total cost.

Managing Complexity in Manufacturing Changeovers: A Sustainable Manufacturing-Oriented Approach and the Application Case Study

2016 ◽  
Author(s):  
Khalid Mustafa ◽  
Kai Cheng
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Business Models ◽  
Sustainable Manufacturing ◽  
Lead Times ◽  
Manufacturing Companies ◽  
Factors Affecting ◽  
Manufacturing Complexity ◽  
Oriented Approach

Increasing manufacturing complexity continues to be one of the most significant challenges facing the manufacturing industry today. Due to these rapid changes in manufacturing systems, one of the most important factors affecting production is recognized as the frequent production setup or changeovers, consequently affecting the overall production lead times and competitiveness of the company. Developing responsive production setup and process capability is increasingly important as product ranges and varieties in manufacturing companies are growing rapidly and, at the same time, production business models are operating more towards being customer-oriented. Furthermore, although different conventional methods have been used to manage complexity in production changeovers, sustainability and competitiveness development in a manufacturing company needs to be scientifically addressed by managing manufacturing complexity. In this paper, a sustainable manufacturing-oriented approach is presented in mind of managing manufacturing changeover complexities. A case study is carried out specifically concerning changeover complexity in a pharmaceutical company, aiming at minimizing complexities in production changeover and waste, increasing plant flexibility and productivity, and ultimately the sustainable competitiveness of the company in managing manufacturing changes.

scholarly journals Managing Manufacturing Complexity Drivers on Performance – An Initial Study

2018 ◽  
Vol 2 (1) ◽  
pp. 45-50
Author(s):  
Keyword(s):  
Strong Correlation ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Initial Study ◽  
Efficient Production ◽  
Product Management ◽  
Nonlinear Behaviour ◽  
Manufacturing Companies ◽  
Manufacturing Performance ◽  
Manufacturing Productivity

Manufacturing systems, in pursuit of cost, time and flexibility optimisation are becoming more and more complex, exhibiting a dynamic and nonlinear behaviour. Unpredictability is a distinct characteristic of such behaviour and effects production planning significantly. Complexity continues to be a challenge in manufacturing systems, resulting in ever-inflating costs, operational issues and increased lead times to product realisation. This challenge must be met with appropriate decision-making by manufacturing companies to secure competitive advantage without compromising sustainability. Assessing complexity realises the reduction and management of complexity sources which contribute to lowering associated engineering costs and time, improves productivity and increases profitability. Therefore, this study was undertaken to investigate the priority level and current achievement of manufacturing performance in Malaysia’s manufacturing industry and the complexity drivers on manufacturing productivity performance. The results showed that Malaysia’s manufacturing industry prioritised product quality and they managed achieved a good on-time delivery performance. However, for other manufacturing performance, there was a difference where the current achievement of manufacturing performances in Malaysia’s manufacturing industry is slightly lower than the priority given to them. The strong correlation of significant value for priority status was observed between efficient production levelling (finished goods) and finish product management while the strong correlation of significant value for current achievement was minimised the number of workstation and factory transportation system. This indicates that complexity drivers have an impact towards manufacturing performance. Consequently, it is necessary to identify complexity drivers to achieve well manufacturing performance.

Simulation of Manufacturing Production Line Based on Arena

2014 ◽  
Vol 933 ◽  
pp. 744-748 ◽  
Author(s):  
Seyed Mojib Zahraee ◽  
Saeed Rahimpour Golroudbary ◽  
Ahmad Hashemi ◽  
Jafar Afshar ◽  
Mohammadreza Haghighi
Keyword(s):  
Computer Simulation ◽  
Simulation Model ◽  
Production Line ◽  
Manufacturing Systems ◽  
Waiting Times ◽  
Controversial Issues ◽  
Manufacturing Companies ◽  
Total Cost ◽  
Manufacturing Line

One of the controversial issues in manufacturing systems is bottleneck. Managers and engineers are trying to find methods to eliminate the bottlenecks and waiting times in the production line. More over the manufacturing companies are striving to sustain their competiveness by decreasing the bottlenecks, total cost and increasing the productivity. The objective of this study is applying the computer simulation to analysis the production line bottlenecks. To achieve this goal a color manufacturing line was selected as a case study and the basic application of arena 13.9 software. Finally the some modifications in the simulation model are proposed to improve the production line as well as to decrease the bottleneck.

A conceptual continuous improvement implementation framework for UK manufacturing companies

2017 ◽  
Vol 34 (7) ◽  
pp. 1015-1033 ◽  
Author(s):  
Richard Scott McLean ◽  
Jiju Antony
Keyword(s):  
Conceptual Framework ◽  
Continuous Improvement ◽  
Manufacturing Industry ◽  
Manufacturing Companies ◽  
Senior Managers ◽  
Implementation Framework ◽  
Content Type ◽  
Robust Solution ◽  
The Uk ◽  
High Level

Purpose The purpose of this paper is to review current continuous improvement implementation models and frameworks, and present a new conceptual framework tailored specifically to the needs of UK manufacturing companies. Design/methodology/approach The paper details the in-depth review of 20 existing models or frameworks for continuous improvement implementation, demonstrating the need for a new industry and region specific solution. Through the incorporation of previous findings from literature, coupled with the positive aspects of the current offerings, a new conceptual framework for continuous improvement implementation in UK manufacturing companies is presented. Findings The paper demonstrates the need for industry and region specific frameworks and demonstrates that current models and frameworks do not completely fulfil the objective of the research. A new continuous improvement implementation framework is therefore presented in a user friendly format, comprising positive aspects of previous models and frameworks where applicable. Research limitations/implications The focus of the research is limited to the UK and the manufacturing industry. It is therefore not clear the applicability of the framework presented to other regions and industries. The framework presented is also conceptual at this stage and requires validation through interview and application. Practical implications The framework presented will provide senior managers wishing to implement continuous improvement an understanding of the high level process, as well as awareness of their role within the roll out. Overall, the framework provides a clear guide whilst also allowing for individual tailoring of the elements contained to the needs of the company. Originality/value The paper presents a new conceptual framework; the first to be tailored to the needs of UK manufacturing companies. The framework has also been demonstrated to be a more robust solution than those currently in existence.

scholarly journals Applying the PDCA Cycle to Reduce the Defects in the Manufacturing Industry. A Case Study

2018 ◽  
Author(s):  
Arturo Realyvásquez-Vargas ◽  
Karina Cecilia Arredondo-Soto ◽  
Teresa Carrillo ◽  
Gustavo Ravelo
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Welding Process ◽  
Manufacturing Companies ◽  
Delivery Times ◽  
Pdca Cycle ◽  
Increasing Demand ◽  
Quality Of Products

Defects are considered one of the wastes in manufacturing systems that negatively affect the delivery times, cost and quality of products leading to manufacturing companies facing a critical situation with the customers and to not comply with the IPC-A-610E standard for the acceptability of electronic components. This is the case is a manufacturing company located in Tijuana, Mexico. Due to an increasing demand on the products manufactured by this company, several defects have been detected in the welding process of electronic boards, as well as in the components named Thru-Holes. It is for this reason that this paper presents a lean manufacturing application case study. The objective of this research is to reduce at least 20% the defects generated during the welding process. In addition, it is intended to increase 20% the capacity of 3 double production lines where electronic boards are processed. As method, the PDCA cycle, is applied. The Pareto charts and the flowchart are used as support tools. As results, defects decreased 65%, 79% and 77% in three analyzed product models. As conclusion, the PDCA cycle, the Pareto charts, and the flowchart are excellent quality tools that help decrease the number of defective components.

Application of Design of Experiment and Computer Simulation to Improve the Color Industry Productivity: Case Study

2014 ◽  
Vol 68 (4) ◽  
Author(s):  
Seyed Mojib Zahraee ◽  
Shahab Shariatmadari ◽  
Hadi Badri Ahmadi ◽  
Saeed Hakimi ◽  
Ataollah Shahpanah
Keyword(s):  
Resource Utilization ◽  
Design Of Experiment ◽  
Production Line ◽  
Controversial Issues ◽  
Full Time ◽  
Manufacturing Companies ◽  
Part Time ◽  
High Level ◽  
Process Productivity

One of the controversial issues in manufacturing companies is bottleneck. Managers and engineers try to deal with this difficulty to improve the productivity such as increasing resource utilization and throughput. One color factory is selected as a case study in this paper. This company tries to identify and decrease the bottlenecks in the production line. The goal of this paper is building the simulation model of production line to improve the productivity by analyzing the bottleneck. To achieve this goal, statistical method named design of experiment (DOE) was performed in order to find the optimum combination of factors that have the significant effect on the process productivity. The analysis shows that all of the main factors have a significant effect on the production line productivity. The optimum value of productivity is achieved when the number of delpak mixer (C) and number of lifter (D) to be located at high level that is equal to 2 and 2 respectively. The most significant conclusion of this study is that 3.2 labors are required to reach maximum productivity based on the resource utilization and cost. It means that 3 full time labors and one part time labor should be employed for the production line. 

scholarly journals Industrial Internet-enabled Resilient Manufacturing Strategy in the Wake of COVID-19 Pandemic: A Conceptual Framework and Implementations in China

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Tao Peng ◽  
Qiqi He ◽  
Zheng Zhang ◽  
Baicun Wang ◽  
Xun Xu
Keyword(s):  
Conceptual Framework ◽  
Emergency Response ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Smart Manufacturing ◽  
Manufacturing Strategy ◽  
Supply Chain Resilience ◽  
Industrial Internet ◽  
Key Enabling Technologies ◽  
High Level

AbstractCOVID-19 pandemic has accelerated the re-shaping of globalized manufacturing industry. Achieving a high level of resilience is thereby a recognized, essential ability of future manufacturing systems with the advances in smart manufacturing and Industry 4.0. In this work, a conceptual framework for resilient manufacturing strategy enabled by Industrial Internet is proposed. It is elaborated as a four-phase, closed-loop process that centered on proactive industry assessment. Key enabling technologies for the proposed framework are outlined in data acquisition and management, big data analysis, intelligent services, and others. Industrial Internet-enabled implementations in China in response to COVID-19 have then been reviewed and discussed from 3Rs’ perspective, i.e. manufacturer capacity Recovery, supply chain Resilience and emergency Response. It is suggested that an industry-specific and comprehensive selection coordinated with the guiding policy and supporting regulations should be performed at the national, at least regional level.

scholarly journals Socially Inclined Engagement and Its Effect on CSR Perception Observed in Manufacturing Companies

2020 ◽  
Vol 8 (5) ◽  
pp. 3244-3251
Keyword(s):  
Employee Engagement ◽  
Structural Equation ◽  
Manufacturing Industry ◽  
Positive Association ◽  
Equation Model ◽  
Partial Least Square ◽  
Least Square ◽  
Manufacturing Companies ◽  
Positive Perception ◽  
High Level

The manufacturing industry majorly constitutes electrical, electronics, telecommunication, mechanical engineering, and textile companies. This sector provides more employment for the skilled level employee than that of service and information technology sectors. Besides, the manufacturing industry significantly contributes to the economy. Hence, the employees working in such companies are expected to be engaged with the goals of the company. A high level of engagement leads to productivity. This study aims to understand the level of socially inclined employee engagement and its impact on the perceived image of the company’s CSR activities. The study uses Partial Least Square – Structural Equation Model (PLS-SEM) to determine the association between employee engagement and CSR activity. The results indicate that there exists a positive association between engagement level and positive perception of CSR activity. The instrument to measure this association is developed and supported with the evidence from reliability tests and validity test

scholarly journals Applying the Plan-Do-Check-Act (PDCA) Cycle to Reduce the Defects in the Manufacturing Industry. A Case Study

2018 ◽  
Vol 8 (11) ◽  
pp. 2181 ◽  
Author(s):  
Arturo Realyvásquez-Vargas ◽  
Karina Arredondo-Soto ◽  
Teresa Carrillo-Gutiérrez ◽  
Gustavo Ravelo
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Welding Process ◽  
Manufacturing Companies ◽  
Delivery Times ◽  
Pdca Cycle ◽  
Increasing Demand ◽  
Quality Of Products

Defects are considered as one of the wastes in manufacturing systems that negatively affect the delivery times, cost and quality of products leading to manufacturing companies facing a critical situation with the customers and to not comply with the IPC-A-610E standard for the acceptability of electronic components. This is the case is a manufacturing company located in Tijuana, Mexico. Due to an increasing demand on the products manufactured by this company, several defects have been detected in the welding process of electronic boards, as well as in the components named Thru-Holes. It is for this reason that this paper presents a lean manufacturing application case study. The objective of this research is to reduce at least 20% the defects that are generated during the welding process. In addition, it is intended to increase 20% the capacity of three double production lines where electronic boards are processed. As method, the Plan-Do-Check-Act (PDCA) cycle, is applied. The Pareto charts and the flowchart are used as support tools. As results, defects decreased 65%, 79%, and 77% in three analyzed product models. As conclusion, the PDCA cycle, the Pareto charts, and the flowchart are excellent quality tools that help to decrease the number of defective components.

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