STABILISATION OF PRODUCTION LINES BY USING OF SIMULATION STUDYMETHODOLOGY
STABILISATION OF PRODUCTION LINES BY USING OF SIMULATION STUDY METHODOLOGY
Mr. sc. Cerjakovi
, Prof. Dr. Tufek
, Prof. Dr. Top
,Prof. Dr. Šelo R.
, Mr. sc.
University of Tuzla, Faculty of Mechanical Engineering Tuzla, B & H
, Engine Development, Volkswagen AG, Germany
Modern business conditions have forced manufacturing companies that want to achieve and maintain their competitive abilitiesin the global market on a permanent optimization of the working parameters and the internal organization of production systems.Continuous increasing of production capacity along with simultaneously reducing of production costs and maintains quality of the product at least the same level can be achieved by this way. One of methodologies that allow simulation of complex production/transportation processes is the simulation study, by whose usage is possible to provide a satisfactory description and efficient optimization of dynamic phenomena within the production systems. In this paper is presented implementation of simulation study methodology on real productionline for production of automotive parts, with code label "Ring 1".
: MATERIAL FLOWS, QUEUING, SIMULATION EXPERIMENT, SIMULATION STUDY, BALANCING
The basic goal of any manufacturing system is theachievement of anticipated production quantity and quality on time.Consequently the planning and operating of production systems areconstantly targeted to reduce production costs in order to increasethe overall effectiveness and achieve an appropriate level of competitiveness at the market. Existing production systems areincreasingly faced with the complex logistical and organizational problems by implementing modern technologies with the aim toreduce production costs. From the viewpoint of material flowswithin the production, above mentioned problems are primarilyrelated to the deviation appearance of the scheduled from the actualcapacity of production/transportation lines. Additionally, a frequent phenomena that occurs in the production are:- bottlenecks, i.e. the imbalance between the particular production and transportation operations;- lower level of utilization degree for production-transportation lines then was planned;- planned storage capacity and buffers does not match tothe actual needs;- significant differences between the theoretical and the planned production capacity, with no valid informationand specific knowledge about dependencies related to production - transportation capacity.To resolve above mentioned issues simulations methods basedon analysis of discrete events are even more in usage. Applicationof those methods allows the better analysis of complexmanufacturing processes. In practice it is often not given carefulattention to the problems of compliance between production andtransportation capacities, as well as to the significant impact of random events (e.g. malfunctions), which cause an inadequate levelof balance within the production line. In addition, in most casesdecisions on whether applied systems of material flows andtransport resources was appropriately selected, are carried out byapplication of the methods for the analysis of material flows, whichdo not take into account the dynamics and stochastic phenomenathat occur in production systems at the real conditions. In relation tothis, for many production systems there are not enough necessaryknowledge about certain internal production-transportation processes, which usually results in the occurrence of unnecessarycosts in the production process. Large part in those costs causesdisproportion of production operations and internal transportationequipment. It should be emphasized that the imbalance between production and internal transportation operations is not always anindicator of the inadequate working parameters of internaltransportation system. Often occur the problems of inappropriateequipment used in the processes of internal transportation, whichmust also be taken into account when considering all abovementioned issues.
In general, it can be said, that every complex system or phenomenon, i.e. processes that contain stochastic, nonlinear or time variable, often can not be describe by a set of deterministicmathematical expressions or equations, and they are usuallyanalysed by modelling and simulating. The term simulation stemsfrom the Latin word "simulare" that means "imitation", which isessentially the main goal of the simulation execution,  and .Simulation models are used for insight access into behaviour of a virtual or real existing production system, which otherwisecould not be achieved by conventional scientific methods, and thus becomes an acceptable device for analysis and design of productionsystems, .
Simulation study methodology
Performing of simulations with the aim to describe the processes within the production systems is characterized byexpression simulation study and defined by Guideline VDI 3633,:
„ Simulation study is a project for systems testing supported by simulation model. (...) Simulation studies may include severalsimulation experiments, which at the other hand can be made up from several simulation passes. “
According to this definition, simulation study consists of thefollowing phases, :1
defining problems, objectives and tasks;2
collecting and processing the input data;3
logical descriptions of the observed process;4
validation and verification of simulation models;5
analysis of the gained results.
In this paper are considered the problems and possiblesolutions for balancing of manufacturing line for production of automotive parts, with code label "Ring 1". Detail informationabout considered topic can be found in the literature states .