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.

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.

Characterization of Manufacturing System Computer Simulation using Taguchi Method

2015 ◽  
Vol 72 (4) ◽  
Author(s):  
Seyed Mojib Zahraee ◽  
Ali Chegeni ◽  
Jafri Mohd Rohani
Keyword(s):  
Computer Simulation ◽  
Taguchi Method ◽  
Manufacturing Industry ◽  
Waiting Times ◽  
Inspection Time ◽  
Total Output ◽  
Service Rate ◽  
Manufacturing Line

In the manufacturing industry, managers and engineers are trying to sustain their competitiveness by achieving high output and productivity. There are some common problems such as waiting times, failures, reworks in production line that impose extra cost to the companies. Therefore, companies are striving to find methods in order to determine and deal with problems using different methods such as mathematical, statistical and computer simulation. The goal of this paper is to increase the total output production and to improve productivity using computer simulation and Taguchi method. This paper introduces a color manufacturing line as a case study which is simulated using arena 13.9 software. Following that the Taguchi method is applied to assess the effect of controllable and uncontrollable factors on the total output production. According to the result of JMP 10 software to conduct Taguchi experiment, the maximum desirability of productivity will be achieved when the value of factors such service rate of delpak machine=UNIF (30, 40), number of labor=14, inspection time=120 and number of Permil=5. Taguchi Method plays an efficient and suitable role in the process improvement, proposing adjustments that will provide an improvement in the productivity. 

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 Application of Computer Simulation for Productivity Improvement of Welding Unit in a Heater Manufacturing Industry: A Case Study Based on Arena

2018 ◽  
Vol 225 ◽  
pp. 01004 ◽  
Author(s):  
Salman Jameh Abrishami ◽  
Mohammad Zeraatkar ◽  
Rasoul Esrafilian ◽  
Seyyed Amir Vafaei ◽  
Seyed Mojib Zahraee
Keyword(s):  
Computer Simulation ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Management Strategies ◽  
Simulation Models ◽  
Global Market ◽  
Productivity Improvement ◽  
Manufacturing Management ◽  
Manufacturing Line

Firm’s efficiency and competitiveness are two important challenges in today’s global market that have motivated many manufacturing firms to plan novel manufacturing management strategies. Nowadays, simulation models have been used to assess different aspects of manufacturing systems. This paper introduces a welding unit of a manufacturing line of heater production as a case study and the basic application of the ARENA software. The main goal of this paper is increasing the productivity of the production line by using computer simulation. To achieve this goal, three various scenarios are compared and suggested to obtain the better improvement in productivity.

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.

Selection of lean manufacturing systems using the PROMETHEE

2008 ◽  
Vol 3 (1) ◽  
pp. 40-70 ◽  
Author(s):  
G. Anand ◽  
Rambabu Kodali
Keyword(s):  
Decision Making ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Strategic Decision ◽  
Computer Integrated Manufacturing ◽  
Preference Ranking ◽  
Manufacturing Strategy ◽  
Manufacturing Companies ◽  
Content Type

PurposeIn recent years, many manufacturing companies are attempting to implement lean manufacturing systems (LMS) as an effective manufacturing strategy to survive in a highly competitive market. Such a process of selecting a suitable manufacturing system is highly complex and strategic in nature. The paper aims to how companies make a strategic decision of selecting LMS as part of their manufacturing strategy, and on what basis such strategic decisions are made by the managers.Design/methodology/approachA case study of a small‐ and medium‐sized enterprise is presented, in which the managers are contemplating on implementing either computer integrated manufacturing systems (CIMS) or LMS. To supplement the decision‐making process, a multi‐criteria decision making (MCDM) model, namely, the preference ranking organisation method for enrichment evaluations (PROMETHEE) is used to analyse how it will impact the stakeholders of the organisation, and the benefits gained.FindingsAn extensive analysis of PROMETHEE model revealed that LMS was the best for the given circumstances of the case.Research limitations/implicationsThe same problem can be extended by incorporating the constraints (such as financial, technical, social) of the organisation by utilising an extended version of PROMETHEE called the PROMETHEE V. Since, a single case study approach has been utilised, the findings cannot be generalized for any other industry.Practical limitations/implicationsThe methodology of PROMETHEE and its algorithm has been demonstrated in a detailed way and it is believed that it will be useful for managers to apply such MCDM tools to supplement their decision‐making efforts.Originality/valueAccording to the authors’ knowledge there is no paper in the literature, which discusses the application of PROMETHEE in making a strategic decision of implementing LMS as a part of an organisation's manufacturing strategy.

scholarly journals Evaluation of SME (Small Medium Enterprise) production system with discrete system simulation method

2018 ◽  
Vol 154 ◽  
pp. 01067
Author(s):  
Reno Dias Anggara Purba ◽  
M Iqbal Sabit ◽  
Joko Sulistio
Keyword(s):  
Production Line ◽  
Discrete System ◽  
System Simulation ◽  
Waiting Times ◽  
Minimum Cost ◽  
Poor Performance ◽  
Simulation Method ◽  
Manufacturing Companies ◽  
Production Lines ◽  
Best Response

Like manufacturing companies that have flowshop production lines, SME facing the amount of flow time and makespan. Unfulfilled production targets, buildup on some machines that result in other machines being idle, increasing waiting times across multiple machines, and poor performance of workers are a series of problems facing SME. This article uses a discrete system simulation method to analyze and evaluate SME production lines to improve performance. Simulation is an appropriate tool used when experiments are needed in order to find the best response from system components. From the results of modeling and simulation done found the root of the problem is due to accumulation that occurs in one machine and the lack of utility of the operator in producing bags. So do the experimental design with 3 scenarios on the system that have been modeled and obtained some solutions that can be offered to solve the problem. Furthermore, after the alternative selection is obtained the best scenario based on the alternative selection test is the scenario3 by adding 2 new machines and 1 new operator on the production line obtained a significant output increase compared to other scenarios of approximately 30%. While the best scenario based on the minimum cost is the scenario2 by adding 2 new operators obtained output that is not much different than the scenario3. However, it has not been able to solve a series of problems facing SME. Therefore, the results of this study to solve a series of problems faced by SME is to add facilities in the production line of 2 new machines and 1 operator (scenario3).

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.

scholarly journals Effect of Calculation of Cost of Production on Selling Price of Products Manufacturing Companies in Papua (Case Study CV. Sagita Grafika)

2016 ◽  
Vol 7 (3) ◽  
pp. 6-10
Author(s):  
Mugiati ◽  
Bosta Sihombing
Keyword(s):  
Secondary Data ◽  
Primary Data ◽  
Selling Price ◽  
Manufacturing Companies ◽  
Labor Costs ◽  
Total Cost ◽  
Method Of Calculation ◽  
The Cost ◽  
Costing Analysis

This study aims to determine how the effect of calculating the cost of an order made by the company and the method of calculation of full costing of the product selling price fixing mold. The data used is primary data, order data produced in the period from January 2013 to December 2013, the secondary data obtained from interviews and literature. From these results it can be seen that CV. Sagita Grafika calculate the cost of the product by using the order cost method that produces cost price and the selling price that is incompatible with existing theory, in which the charging of indirect labor and overhead costs shared equally on all types of orders in the amount of Rp. 11.78825 million for indirect labor costs and Rp. 3.1243 million for overhead costs so that volume orders will bear fewer overhead costs equal to the volume of orders more. By using a full costing analysis generated calculation method that the volume of orders that more will earn imposition overhead costs more, because in this calculation loading overhead costs charged by direct labor hours incurred for each order. So that orders with a total volume that many will use a lot of labor hours and vice versa. So in this study that most large orders received charging overhead is the order BS-02 Rp. 31,115,590.92 and most orders received little overhead loading is KK-01 orders in the amount of Rp. 2,208,622.32. Results of a comparison between the cost of the company with the full costing is the total cost of less Rp. 27,499,540.57, the selling price of Rp. 5,866,543.90, while the larger profit generated by using the full costing method that is Rp. 21,632,996.67

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