Simulation Based Analysis of Reconfigurable Manufacturing System Configurations

Gola, Arkadiusz; Świć, Antoni

doi:10.4028/www.scientific.net/amm.844.50

Cited by 13 publications

(10 citation statements)

References 13 publications

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“…The literature acknowledges the importance of applying digital technologies such as CPSs in RMSs for addressing the dynamic behaviour of materials and information. It suggests that applying a CPS in the CA of RMSs contributes to rapid response and improves the productivity, responsiveness and cost of manufacturing systems [27,39,66]. However, recent research efforts have overlooked material handling, an essential aspect for addressing dynamic behaviour of RMS [67].…”

Section: Identi Ed Gap and Research Questionsmentioning

confidence: 99%

Enabling CPS and simulation-based multi-objective optimisation for material handling of reconfigurable manufacturing systems

Flores-García

Díaz²,

Wiktorsson³

et al. 2023

Preprint

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Reconfigurable manufacturing systems (RMS), cyber-physical systems (CPS) and simulation-based multi-objective optimisation (SMO) are essential for addressing the dynamic behaviour of materials and information in manufacturing. However, the lack of consideration for material handling jeopardises recent advances in these fields. Accordingly, this study proposes the use of CPSs including SMO to address the dynamic allocation of resource of material handling in the configuration analysis (CA) of RMSs and enhance operational performance. We focus on CA because of its influence on the arrangement of machines, equipment selection, and operational assignments, influencing the performance of RMS. The study presents a proof-of-concept CPS and SMO in a laboratory environment for evaluating trade-off solutions including throughput, buffer capacity, lead-time, and resources in material handling. This study contributes to the existing literature in three ways. First, it proposes a CPS architecture that includes physical, cyber, and digital service layers for applying SMO in the CA of RMS. Second, it presents a procedure for SMO, including initialization, environment, optimisation engine, and outputs, and applies NSGA-II to improve the existing calculations of the CA of RMS. Third, it shows benefits the operational performance of applying CPS and SMO to address the dynamic behaviour of material handling in the CA of RMS.

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Section: Identi Ed Gap and Research Questionsmentioning

confidence: 99%

Enabling CPS and simulation-based multi-objective optimisation for material handling of reconfigurable manufacturing systems

Flores-García

Díaz²,

Wiktorsson³

et al. 2023

Preprint

View full text Add to dashboard Cite

show abstract

“…Moreover, it must be designed for reconfiguration when necessary. This reconfiguration requires installation cost and cost in the start-up phase, characterized by malfunctions and breakdowns of these machines [8].…”

Section: Reconfigurable Manufacturing Systemsmentioning

confidence: 99%

Availability Analysis of Reconfigurable Manufacturing System Using Simulation-Based Multi-Objective Optimization

Díaz

Navarro

Perez

et al. 2022

Advances in Transdisciplinary Engineering

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Nowadays, manufacturing companies face an increasing number of challenges that can cause unpredictable market changes. These challenges are derived from a fiercely competitive market. These challenges create unforeseen variations and uncertainties, including new regional requirements or regulations, new technologies and materials, new market segments, increasing demand for new product features, etc. To cope with the challenges above, companies must reinvent themselves and design manufacturing systems that seek to produce quality products while responding to the changes faced. These capabilities are encompassed in Reconfigurable Manufacturing Systems (RMS), capable of dealing with uncertainties quickly and economically. The availability of RMS is a crucial factor in establishing the production capacity of a system that considers all events that could interrupt the planned production. The impact of the availability in RMS is influenced by the configuration of the systems, including the number of resources used. This paper presents a case study in which a simulation-based multi-objective optimization (SMO) method is used to find machines’ optimal task allocation and assignment to workstations under different scenarios of availability. It has been shown that considering the availability of the machines affects the optimal configuration, including the number of resources needed, such as machines and buffers. This study demonstrates the importance of the availability consideration during the design of RMS.

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“…On the other hand, simulation techniques are considered powerful and supportive when designing and evaluating manufacturing systems [5]. In a broad sense, simulation can be described as an imitation or replica of the operations of a real process or production system over time [16]. To facilitate the simulation process and computing performance, in DES models, the state variables only change at specific discrete points of time when significant events occur, resulting from activity times and delays [17].…”

Section: Reconfigurable Manufacturing Systems and Discrete-event Simu...mentioning

confidence: 99%

“…Previous studies have used DES to support the design and management of RMS in different ways. Studies such as [16] and [19] have employed DES to model and analyze different RMS configurations. Such studies concluded that DES facilities the modelling process and the sequencing of the operations when comparing different RMS configurations.…”

Section: Reconfigurable Manufacturing Systems and Discrete-event Simu...mentioning

confidence: 99%

Reconfiguration Assessment for Production Volume Changes Using Discrete-Event Simulation: A Large-Size Highly-Customized Product Case Study

Zúñiga

Díaz

Navarro

et al. 2022

Advances in Transdisciplinary Engineering

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Globalization and mass customization are commonly translated into increased levels of complexity in manufacturing systems. One of the main reasons is the increased number of variables, parameters, and interrelations on the shop floor. This intrinsic complexity can grow exponentially when considering the manufacture of large-size products with high levels of variability and variants: the mass production of large recreational motorboats with high levels of customization and low production volumes, mass customization. With the increasing role of sustainability and concepts of Industry 5.0, focusing not just on improving production systems but also human wellbeing, quick decision making becomes essential. Data and digitalization are becoming the cornerstone for system improvement, and digital data availability and analysis can facilitate the utilization of computerized tools to support decision making and maximize the performance of complex systems. For that purpose, simulation can be a powerful analytical tool to design, maintain, and improve complex manufacturing systems. Simulation techniques usually allow handling the size and complexity commonly associated with manufacturing systems. However, in systems with highly customized and large-size products, manual processes, and limited floor space, the implementation of simulation techniques is not straightforward, especially considering the aspects of variability, data collection, model validation, and system reconfiguration. With a particular focus on large-size products and limitations of a constrained existing facility layout, this paper presents the implementation of a simulation-based reconfiguration assessment considering manual production, assembly, and internal logistics requirements. Going through an industrial case study of large recreational motorboats manufacturing, the paper analyses the system analysis, data collection, implementation, and validation of the methodology step by step. Considering different what-if scenarios, the focus is on the capacity reconfiguration using Discrete-Event Simulation. The results can serve as a guideline for decision-makers and stakeholders working with complex mass customization manufacturing systems and space-constrained facility layouts.

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Simulation Based Analysis of Reconfigurable Manufacturing System Configurations

Cited by 13 publications

References 13 publications

Enabling CPS and simulation-based multi-objective optimisation for material handling of reconfigurable manufacturing systems

Enabling CPS and simulation-based multi-objective optimisation for material handling of reconfigurable manufacturing systems

Availability Analysis of Reconfigurable Manufacturing System Using Simulation-Based Multi-Objective Optimization

Reconfiguration Assessment for Production Volume Changes Using Discrete-Event Simulation: A Large-Size Highly-Customized Product Case Study

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