Visual Control and Manufacturing System Performance Enhancement Using ARENA Modular Simulation and TECNOMATIX Modeling

Abstract

Just- In - Time (JIT) systems are kanban-controlled production systems where the flow of material is controlled by the presence or absence of a kanban, and where kanbans travel in the system according to certain rules. Furthermore, the manufacturing operations face considerable uncertainty and were considered stochastic due to uncertainty in timing customer orders, variability in the processing time, rework, and scrap rate, inaccuracy of demand forecasting and uncertainty of equipment failure. This study investigated effect of trigger point on cycle time and Work in Process (WIP), effect of number of kanbans on flow time and orders satisfied. Several factors such as number of buffers, location of buffers and scheduling rules are investigated. This study utilized TECHNOMATIX software and a modified version of ARENA’s existing “Electronic Assembly and Test System with Part Transfers” as a baseline model. Results also indicate that Net Operating Income (NOI) differs significantly for manufacturing system (F(2, 1593)=1704.381, p=.000, ήp2=.682), manufacturing overhead level (F(2, 1593)= 31768.716, p=.000, ήp2=.976), and product mix complexity (F(2, 1593)=20449.024, p=.000, ήp2=.963). Manufacturing overhead level did not have a significant impact on Demand Fulfillment Rate (DFR) [F(2, 1593)=.038, p=.962, ήp2 =.000] or average cycle-time [F(2, 1593)=.014, p=.986, ήp2 =.000], nor do any of its interactions significantly affect DFR or average cycle-time. The enhancement of trigger points, Kanban number and scheduling rules should be further explored to improve WIP, lead time and the utilisation of facilities.