Bottleneck Analysis and System Improvement with Simulation Method in a Manufacturing Facility

Abstract

Achieving improvements in production processes requires analyzing the processes and identifying bottlenecks based on actual process data. Simulation is a widely applied method in analyzing the current state of production systems, identifying bottlenecks, developing alternative scenarios to improve throughput and resource utilization, and evaluating these scenarios’ performances. In this study, a discrete event simulation model of a stator production line of a company that produces electrical motors has been developed using AnyLogic software. The analyzed production line is a flow-type production line that consists of 8 machines and 11 operators. This study aims to detect the bottlenecks and determine a flow that maximizes resource utilization rates and minimizes inventory holding costs. The model parameters have been prepared with input analysis using the actual data from the past year of the line. The current state of the line revealed by running the simulation model has been analyzed. The findings have indicated that the winding machine is the bottleneck of the production line. The ideal production quantity of the winding machine has been determined by focusing on the productivity of the line and the utilization rates of resources to improve the system performance. Moreover, an alternative layout for the line has been suggested. Finally, the projected gains with this layout have been evaluated in terms of operator utilization rate.

Keywords

• Discrete event simulation
• AnyLogic
• Bottleneck analysis
• Resource utilization
• Throughput
• Process improvement.
• Discrete event simulation, AnyLogic, Bottleneck analysis, Resource utilization, Throughput, Process improvement.

Bir Üretim İşletmesinde Simülasyon Yöntemi ile Darboğaz Analizi ve Sistem İyileştirmesi

Öz

Üretim süreçlerinde iyileştirmelerin yapılabilmesi ve performans artışının sağlanabilmesi için sistemin mevcut durumunun gerçek süreç verileriyle ortaya konması ve süreçte aksaklık yaratan noktaların tespit edilebilmesi gerekmektedir. Üretim sistemlerinde mevcut durumun analiz edilmesi, darboğazların belirlenmesi, çıktı miktarı ve kaynak kullanımını iyileştirecek önerilerin ortaya konması ve değerlendirilebilmesinde simülasyon sıklıkla başvurulan bir yöntemdir. Bu çalışmada elektrik motoru üreten bir firmanın bir stator yarı mamul üretim hattının, AnyLogic yazılımı kullanılarak kesikli olay simülasyon modeli geliştirilmiştir. Ele alınan hatta 8 makine ve 11 operatör kaynağı kullanılarak akış tipi üretim gerçekleştirilmektedir. Model ile darboğaz belirleme ve hatta kaynak kullanım oranlarını maksimize eden ve stok maliyetlerini minimize eden akışın oluşturulması amaçlanmaktadır. Model parametreleri, hatta ilişkin geçmiş bir yıllık veriler kullanılarak yapılan girdi analizi ile hazırlanmıştır. Simülasyon modelinin çalıştırılması ile mevcut durum analiz edilmiştir. Bulgular, hatta yer alan sarım makinesinin darboğaz olduğuna işaret etmektedir. Sistem performansını iyileştirmek için, hattın verimliliği ve kaynakların kullanım oranlarına odaklanılarak, sarım makinesinin ideal üretim miktarı belirlenmiştir. Ayrıca, hat için yeni bir yerleşim önerisinde bulunularak bu önerinin operatör kullanım oranına katkısı değerlendirilmiştir.

Anahtar Kelimeler

• Kesikli olay simülasyonu
• Darboğaz analizi
• Kaynak kullanımı
• Çıktı miktarı
• Sistem iyileştirme
• Kesikli olay simülasyonu, AnyLogic, Darboğaz analizi, Kaynak kullanımı, Çıktı miktarı, Sistem iyileştirme

Kaynakça

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