The Use of Simulation Optimization in Analyzing the Productivity Problem from a Closed-loop Conveyor System:the Case of Powder Coating

  • 王 美琄

Student thesis: Doctoral Thesis

Abstract

This research aims to solve a nonreversible continuous closed-loop conveyor system The work pieces usually move by carriers which are attached to the conveyor and processed in a constant speed after loaded at the specific station For such a capacitated production system due to the restricted speed of conveyor primary we carry out Gemba Kaizen to eliminate the waste through the conception of lean management Next we implement a discrete-event simulation that attempt to optimize the staffing level and allocation to reduce the production loss caused by machine interference problem This research verifies the solution performance through a case study in a powder coating process of a general metal manufacturer with fixed staffing level in 32 After the verification and improvement in the practical system the preliminary result shows the Gemba Kaizen can release 80 square meters for flexible space in our case study In addition 47% daily transportation time as well as 47 minutes for staffing time can be reduced Based on those results we further make appropriate assumptions and propose a simulation optimization experiment According to the numerical analysis we can achieve the 89% throughput rate while improving staffing utilization and reducing the staffing level to 26 on the premise of the present situation with staffing level in 32 The staffing level improvement can up to 18 8% and staffing utilization improvement between 15% to 28% Furthermore we verify the validity of this research through the sensitivity analysis
Date of Award2020
Original languageEnglish
SupervisorTaho Yang (Supervisor)

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