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Pull system implementation with help of simulation tools
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Problem Statement
Low-current domestic and industrial appliances manufacturer from Poland wanted to reduce production costs and to higher capacity of its production line. |
Improvement Approach
Modelling and simulation was applied to verify an existing system and to develop a structure of a desired one based on pull strategy. |
Benefits
More flexible production system was achieved with less and controllable inventories. New assembly layout was possible due to newly developed logic flow (reduction of some of the storage areas) and layout optimisation. |
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Contact information
Centre for Advanced Manufacturing Technologies
MSc. (Eng.) Lech Siwa, Spółdzielnia Inwalidów „SPAMEL”, 56-416 Twardogóra
Phone +48 71 3158 201 ,
Fax
+48 71 3159 068
e-mail
lechu1122@poczta.onet.pl
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Fot. Spamel |
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Low-current domestic and industrial appliances manufacturer from Poland wanted to reduce production costs and to higher capacity of its production line.New manufacturing system layout was designed by means of chosen modelling and simulation tools.
Chosen design options were as follows:
1.Pull system implementation
2.Minimum re-loads and data processing
3.Minimal distances
4.One-way material movement flow |
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In the first step product representatives were chosen and existing shop-floor’s structure to scale was modelled. Hence material flow distances and corresponding intensities could have been examined.A procedure of simplifying the material route was proposed. The following steps were undertaken:
1.The new material flow logic was proposed in order to enable one-way material flow as well as to minimise the number of batch re-loads.
2.Consequently, the need for some storage areas was neglected.
3.Optimisation software was used in order to determine the desired layout of the factory. The distances between the subsequent processes were optimised and thus minimised.
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4.Production and assembly equipment was grouped in U-shaped cells with the aim of more flexible production control.
5.Each of the assembly cells was designed to be able to serve the assembly of every product family manufactured by the company.
6.The new layout respected the design of transportation paths for transportation services to be able to easily reach supply and collecting points of the assembly cells. |
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Changes resulting from chosen design parameters caused shortening assembly lead-time by almost 60%.The inventory levels that could have been observed in between single assembly processes were eliminated.As a result more flexible production system that could better react to customer orders was achieved with less and controllable inventories. |
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