Robust production planning and control for multi-stage systems with flexible final assembly lines

Production planning of final assembly systems is a challenging task, as the often fluctuating order volumes require flexible solutions. Besides, the calculated plans need to be robust against the process-level disturbances and stochastic nature of some parameters like manual processing times or machine availability. In the paper, a simulation-based optimisation method is proposed that utilises lower level shop floor data to calculate robust production plans for final assembly lines of a flexible, multi-stage production system. In order to minimise the idle times when executing the plans, the capacity control that specifies the proper operatorâtask assignments is also determined. The analysed multi-stage system is operated with a pull strategy, which means that the production at the final assembly lines generates demands for the preceding stages providing the assembled components

Simulation-based Production Planning and Execution Control for Reconfigurable Assembly Cells

In order to meet the continuously changing market conditions and achieve economy of scale, a current trend in the automotive industry is the application of modular reconfigurable assembly systems. Although they offer efficient solution to meet the customers needs, the management of these systems is often a challenging issue, as the continuous advance in the assembly technology introduces new requirements in production planning and control activities. In the paper, a novel approach is introduced that enables the faster introduction of modular assembly cells in the daily production by offering a flexible platform for evaluating the system performance considering dynamic logistics and production environment. The method is aimed at evaluating different modular cell configurations with discrete-event simulation, applying automated model building and centralized simulation model control. Besides, the simulation is linked with the production and capacity planning model of the system in order to implement a cyclic workflow to plan the production and evaluate the system performance in a proactive way, before releasing the plan to the production. The method and the implemented workflow are evaluated within a real case study from the automotive industry

Simulation support in construction uncertainty management: A production modelling approach

The execution of construction projects such as a highway construction or the elevation of a new bridge is a complex, highly equipment-intensive process and are subject to many different uncertainties. This is very similar to the manufacturing execution level in production systems where predefined productions plans and schedules cannot be completely implemented due to unexpected internal and external changes and disturbances. Following this analogy, the paper proposes the application of a discrete-event simulation based method which was already applied in the decision-support for manufacturing control to develop the decision-support in the execution of a construction project where the effects of the deviation from the short-term schedule can be easily and quickly analyzed

Milkrun Vehicle Routing Approach for Shop-floor Logistics

In large-scale shop floors and manufacturing environment, different transportation systems are applied in order to satisfy the material requirements of the systems. The limited capacity of vehicles and time consumption of the logistics processes require effective vehicle routing approaches so as to support production without glitches. The paper gives an overview of the appropriate models and the most efficient solver algorithms of the vehicle routing problem (VRP), introduces a novel approach that uses a novel initial solution generation heuristics, and presents a local search method to solve the VRP. In order to demonstrate the capabilities of the solution proposed, the implemented software concentrates on the main industrial requirements like quick response, effective layout definition and order handling. A specific layout representation scheme is proposed which ensures interoperability between different factory-, and shop-floor planning software products