An integrated simulation–optimization study for consolidating production lines in a configure-to-order production environment
This study investigates production lines consolidation in a configure-to-order production environment using simulation and optimization strategies. The current production environment has three separate production lines that will be consolidated into two production lines. Two production line configurations are analyzed: product and process layouts. Product layout has a continuous smooth flow, small work-in-process (WIP), short total production time per unit of product, and reduced material handling requirements. On the contrary, process layout offers more flexibility, allows for higher utilization of machines, and requires higher grades of operators’ skills. A simulation-based comparison of the current and future systems is conducted considering lead time, throughput, utilization, and WIP. A mixed integer programming model that optimizes the transportation cost and waiting time is then formulated based on the selected process layout. Simulation results provide recommendations to improve the system level performance measures and support management decisions. The current transportation schedule is ineffective, and hence a real-time dashboard based on the optimization model is suggested. The dashboard will improve communication and transportation between the two production lines.
Production capacity analysis of a shock absorber assembly line using simulation
This paper reports findings of a study of shock absorber assembly line using computer simulation. The shock absorber assembly line feeds shockers to the motorcycle assembly line. The assembly line simulated in this project is located at an OEM for Bajaj Auto Ltd., the largest producers of scooters and motorcycles in India. In this paper, results of simulation are presented from two scenarios. The first is the original layout of the system. The second simulation is the suggested modifications. Data was gathered and evaluated to determine the necessary parameters to be used. The new demand required the OEM to increase its capacity by 200 shock absorbers per day. After implementing the proposed model the daily output increased by 435 shock absorbers. The highlights of our analysis was that this increase in production rate was achieved without any increase in direct labor, contributing to a gross increase in profit by 32%.
Performance Evaluation of Fuzzy Routing Algorithms for a New Fuzzy Mixed Metric Approach
Optimizing routing decisions has been an important subject in research of communication networks. The present paper is introducing a new fuzzy mixed metric approach, which takes routing decisions based on fuzzy costs in parallel to crisp cost of other metrics. The present paper evaluates the new fuzzy approach for its performance. The paper first describes the new fuzzy approach and the fuzzy routing algorithms developed for the approach and then the performance is evaluated both in empirical and analytical terms to show its advantages over the previous fuzzy approaches and traditional link- state routing approach. The paper analyzes the performance for different cases to show the efficacy of load on delay. The present paper bargains with three such cases.