On Reduction of Production Disturbances in Manufacturing Systems Based on Discrete-Event Simulation
(2004)- Abstract
- Improved efficiency in manufacturing systems to achieve increased output and thus reduced production disturbances is a vital area. DES (Discrete-Event Simulation) can visualize and study the dynamic issues related to total efficiency in manufacturing systems. A methodology for production disturbance reduction is presented. Increased performance of manufacturing systems means not only enhanced value for the company but in the long run for the society as a whole. Manufacturing companies are the basis of a country which many other activities rely on.
Different production improvement techniques, for example TPS (Toyota Production System), have been shown to smoothe production flows and raise overall quality. Implementation... (More) - Improved efficiency in manufacturing systems to achieve increased output and thus reduced production disturbances is a vital area. DES (Discrete-Event Simulation) can visualize and study the dynamic issues related to total efficiency in manufacturing systems. A methodology for production disturbance reduction is presented. Increased performance of manufacturing systems means not only enhanced value for the company but in the long run for the society as a whole. Manufacturing companies are the basis of a country which many other activities rely on.
Different production improvement techniques, for example TPS (Toyota Production System), have been shown to smoothe production flows and raise overall quality. Implementation of production disturbance reduction ideas must be conducted according to all basic rules of manufacturing. Contemporary production improvement techniques based on supply chains between different suppliers and limited products in stock make it necessary to focus on production disturbance reduction.
The presented methodology is based on three main stages: (1) planning and data gathering, (2) analysis and implementation, and (3) continuous improvement. The planning stage includes project plan, goal and objectives of the study, definition of production disturbances, gathering of input data and logics and the conceptual model. The analysis and implementation stage comprises DES model translation, verification, validation, and experiments. The experiments are based on alternative tests in production disturbance reduction to increase equipment efficiency. The enhanced results in the model should be verified before they are implemented in the real world.
Continuous improvement of the proposed methodology includes improvement in model design, studies of production improvement techniques, training of operators, follow-up of implemented changes, investigations in measurement of production disturbances and key figures. The improvement process is a continuing procedure. A model is seldom so good that it yet can not still be improved. With feedback various variables can be altered and the DES model can be improved in several phases.
The potential of the methodology was shown in several case studies. The industrial case studies showed improved performance of 6%, 12%, 14%, 18%, respectively. No larger investments were needed to increase the performance. The suggested methodology may enable in increase of total output in a manufacturing system if it is applied. (Less) - Abstract (Swedish)
- Popular Abstract in Swedish
Förbättrad effektivitet i tillverkningssystemen för att åstadkomma förbättrad output och sålunda reducera tillverkningsstörningarna är ett viktigt område. Händelsestyrd simulering kan visualisera och studera de dynamiska förloppen relaterade till total effektivitet i tillverkningssystemen. En metodik för reducering av produktionsstörningar är presenterad. Förbättringar i prestanda av tillverkningssystemet betyder inte bara förbättrat resultat för företaget utan även för hela samhället. Tillverkningsindustrin är basen för ett land vilket andra aktiviteter också vilar.
Olika produktionsförbättringstekniker, som till exempel TPS (Toyota Produktionssystem), har visat sig att jämna... (More) - Popular Abstract in Swedish
Förbättrad effektivitet i tillverkningssystemen för att åstadkomma förbättrad output och sålunda reducera tillverkningsstörningarna är ett viktigt område. Händelsestyrd simulering kan visualisera och studera de dynamiska förloppen relaterade till total effektivitet i tillverkningssystemen. En metodik för reducering av produktionsstörningar är presenterad. Förbättringar i prestanda av tillverkningssystemet betyder inte bara förbättrat resultat för företaget utan även för hela samhället. Tillverkningsindustrin är basen för ett land vilket andra aktiviteter också vilar.
Olika produktionsförbättringstekniker, som till exempel TPS (Toyota Produktionssystem), har visat sig att jämna ut produktionsflödena och förbättra kvaliteten på produkterna. Implementering av förbättringsförslag inom störningsreducering måste genomföras enligt gängse regler inom tillverkning. Nutida förbättringsmetoder baserade på tillverkningskedjor mellan leverantörerna och begränsade lager gör det nödvändigt att fokusera på reducering av produktionsstörningar.
Den presenterade metodiken är baserad på tre stadier: (1) planering och datainsamling, (2) analys och implementering, och (3) ständiga förbättringar. Planeringsstadium inkluderar projektplan, mål och syften av studien, definition av produktionsstörningar, insamling av indata och logik och den konceptuella modellen. Analys- och implementeringsstadium innehåller översättning till det händelsestyrda simuleringsprogrammet, verifiering, validering, och experiment. Experimenten är baserade på alternativa test i produktionsstörningsreducering i syfte att förbättra utrustningseffektiviteten. De förbättrade resultaten i modellen skall verifieras innan de implementeras i det verkliga systemet.
Ständiga förbättringar av den föreslagna metodiken innebär förbättringar av modellbyggande, studier av produktionsförbättringstekniker, utbildning av operatörer, uppföljning av införda förändringar, studier i mätningar av produktionsstörningar och nyckeltal. Förbättringsprocessen är en kontinuerlig procedur. En modell är sällan så bra att den inte kan förbättras ännu mer. Med återkoppling kan olika variabler ändras och simuleringsmodellen kan förbättras i olika faser.
Metodiken har visats i flera fallstudier. De industriella fallstudierna har visat på ökad prestanda på respektive 6%, 12%, 14% och 18%. Inga större investeringar behövdes för att öka prestanda. Den föreslagna metodiken kan leda till ökning i total output i ett tillverkningssystem om den tillämpas. (Less)
Please use this url to cite or link to this publication:
https://lup.lub.lu.se/record/467483
- author
- Ingemansson, Arne LU
- supervisor
- opponent
-
- Professor Jackson, Mats, Mälardalens högskola, Eskilstuna
- organization
- publishing date
- 2004
- type
- Thesis
- publication status
- published
- subject
- keywords
- Automatiska system, robotteknik, reglerteknik, Production technology, Produktionsteknik, control engineering, robotics, Automation, manufacturing system, Discrete-event simulation (DES), production disturbance reduction
- pages
- 178 pages
- defense location
- Room M:E, M-building, Lund Institute of Technology.
- defense date
- 2004-10-28 10:15:00
- external identifiers
-
- other:ISRN:LUTMDN/(TMMV-1057)/1-178/2004
- ISBN
- 91-628-6149-2
- language
- English
- LU publication?
- yes
- additional info
- Article: 1: Reducing bottlenecks in a manufacturing system with automatic data collection and discrete-event simulation. Arne Ingemansson, Torbjörn Ylipää, Gunnar Bolmsjö Article: 2: Improved efficiency with production disturbance reduction in manufacturing systems based on discrete-event simulation. Arne Ingemansson, Gunnar Bolmsjö Article: 3: Increasing performance efficiency in manufacturing systems with production improvement techniques and discrete-event simulation. Arne Ingemansson, Johan Ericsson, Gunnar Bolmsjö Article: 4: A survey of the use of the discrete-event simulation in manufacturing industry. Arne Ingemansson, Gunnar Bolmsjö, Ulrika Harlin Article: 5: Increase the total input when disturbances are reduced in a manufacturing system. Arne Ingemansson, Gunnar Bolmsjö The information about affiliations in this record was updated in December 2015. The record was previously connected to the following departments: Robotics (ceased) (LUR000026)
- id
- 7fe1b5f2-7fa9-4e26-9c33-034dc2347437 (old id 467483)
- date added to LUP
- 2016-04-04 14:10:07
- date last changed
- 2018-11-21 21:18:41
@phdthesis{7fe1b5f2-7fa9-4e26-9c33-034dc2347437,
abstract = {{Improved efficiency in manufacturing systems to achieve increased output and thus reduced production disturbances is a vital area. DES (Discrete-Event Simulation) can visualize and study the dynamic issues related to total efficiency in manufacturing systems. A methodology for production disturbance reduction is presented. Increased performance of manufacturing systems means not only enhanced value for the company but in the long run for the society as a whole. Manufacturing companies are the basis of a country which many other activities rely on.<br/><br>
<br/><br>
Different production improvement techniques, for example TPS (Toyota Production System), have been shown to smoothe production flows and raise overall quality. Implementation of production disturbance reduction ideas must be conducted according to all basic rules of manufacturing. Contemporary production improvement techniques based on supply chains between different suppliers and limited products in stock make it necessary to focus on production disturbance reduction.<br/><br>
<br/><br>
The presented methodology is based on three main stages: (1) planning and data gathering, (2) analysis and implementation, and (3) continuous improvement. The planning stage includes project plan, goal and objectives of the study, definition of production disturbances, gathering of input data and logics and the conceptual model. The analysis and implementation stage comprises DES model translation, verification, validation, and experiments. The experiments are based on alternative tests in production disturbance reduction to increase equipment efficiency. The enhanced results in the model should be verified before they are implemented in the real world.<br/><br>
<br/><br>
Continuous improvement of the proposed methodology includes improvement in model design, studies of production improvement techniques, training of operators, follow-up of implemented changes, investigations in measurement of production disturbances and key figures. The improvement process is a continuing procedure. A model is seldom so good that it yet can not still be improved. With feedback various variables can be altered and the DES model can be improved in several phases.<br/><br>
<br/><br>
The potential of the methodology was shown in several case studies. The industrial case studies showed improved performance of 6%, 12%, 14%, 18%, respectively. No larger investments were needed to increase the performance. The suggested methodology may enable in increase of total output in a manufacturing system if it is applied.}},
author = {{Ingemansson, Arne}},
isbn = {{91-628-6149-2}},
keywords = {{Automatiska system; robotteknik; reglerteknik; Production technology; Produktionsteknik; control engineering; robotics; Automation; manufacturing system; Discrete-event simulation (DES); production disturbance reduction}},
language = {{eng}},
school = {{Lund University}},
title = {{On Reduction of Production Disturbances in Manufacturing Systems Based on Discrete-Event Simulation}},
year = {{2004}},
}