SUNConferences, Computers and Industrial Engineering 42

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Bottleneck Management Through Discrete Event Simulation For Manual Automobile Assembly Systems
Mendon Dewa, Liberty Chidzuu

Last modified: 2012-06-20


Batch model lines are quite handy when the demand for each product is medium. However they are characterized by high work-in-progress inventories, lost production time when changing over models and reduced flexibility when it comes to altering production rates as product demand changes. On the other hand, mixed model lines can offer reduced work-in-progress inventory and increased flexibility. The object of this paper is to illustrate that a manual automobile assembling system can be optimized through bottleneck management by ensuring high workstation utilization, reducing queue lengths before stations as well as reducing station downtime. A case study from the automobile industry is used for data collection. A model is developed through use of simulation software.  The model is then verified and validated before a detailed bottleneck analysis is conducted. An operational strategy is then proposed for optimal bottleneck management. Although the paper focuses on improving automobile assembly systems in batch mode, the methodology used can also be applied in single model manual and automated production lines. 

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