Optimisation of the Logistics System in an Electric Motor Assembly Flowshop by Integrating the Taguchi Approach and Discrete Event Simulation

Abstract

An electric motor assembly flowshop (EMAF) is a type of classical mixed-product assembly line that uses automatic guided vehicle (AGV) systems for material handling. To optimise the logistics system configuration and alleviate the impact of the AGV parameters on the efficiency of the EMAF, a modelling and optimisation method based on discrete event simulation (DES) combined with Taguchi orthogonal experimental design was proposed. A DES model of the entire production process for the EMAF was constructed using the Tecnomatix Plant Simulation software package. After optimisation of the principal layout in the DES model, the number of assembly stations was decreased from 13 to 9, and the balance ratio was increased from 65.08% to 84.65%. In addition, the combination of the Taguchi method with the DES model was further developed to achieve the optimal parameter combination of the AGVs in order to allow the AGVs to operate more efficiently under various states. The final overall theoretical throughput was increased from 134 to 295 units within the seven-hour observation period.

Increasing the Efficiency of the Assembly Process Using the FMEA Method and Dynamic Simulation

“…The proper functioning and operation of logistics processes requires the possession of information that will be the basis for identifying errors and detecting existing bottlenecks [2]. Their knowledge will subsequently enable to implement appropriate measures to ensure their efficient operation and process optimization [3].…”