A Study on Applying System Simulation and DBR Technology to Manufacturing Process Improvement

• Main Authors: LIN,YAN-TING, 林彥廷
• Other Authors: Dr. Liao, Li-Man
• Format: Others
• Language: zh-TW
• Published: 2018
• Online Access: http://ndltd.ncl.edu.tw/handle/3972t3

碩士 === 國立勤益科技大學 === 工業工程與管理系 === 106 === This research applies system simulation technology and Theory of Constraint (TOC) to the improvement of the precision locknuts production system. In this research, the current manufacturing processes are analyzed and the simulation model is established so as to find the bottleneck process and idle resources. The proposed improvement plans are assessed with system simulation analysis to estimate the potential benefits. First, the production data and the status of order demand are sorted out via the collection of internal process data of the case company. Especially focusing on the analysis of process and core products, the simulation software Flexsim is used to simulate the environment of plant area and attempt to find out the bottleneck and the problems of current processes. The concept of TOC is then applied to propose bottleneck process improvement plans. The bottleneck is thread-cutting process. The overtime of the bottleneck should be 10 hours per week, it will increase a capacity of 100 machine hours. The cycle time will be shortened from 8 to 5 days. There are four improving plans proposed for solving the problems of insufficient machine utilization. Drum-Buffer-Rope (DBR) method is applied to schedule on the bottleneck process, and Flexsim is used to evaluate the potential benefit for each plan and find out the best one for the case company. The simulation results show that the cycle time is shortened 3 days, the number of machine is decreased by 5, the rate of line balancing is moved up 11.3%, the utilization rate of machine is increased 14%, and the work in process (WIP) is decreased 3,592 units. The improvement benefit of the proposed plan is significant.