The use of discrete-event simulation and lean methodologies in solving variable unit-load production system-A case study of fishing nets production
| Autor: | Yu-tung Lai, 賴昱彤 |
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| Rok vydání: | 2008 |
| Druh dokumentu: | 學位論文 ; thesis |
| Popis: | 96 The final purpose of the lean production system is to satisfy customer's needs. Therefore, the flexible of production lines becomes a critical issue after production pattern has been changed from mass production to small-volume with large variety production. The manufacturing system of lean production is using management methods to survey the waste of production lines, to execute some kinds of improvability actions of reducing the cost, and to elevate productivity and quality to support various customization productions. By using lean production system, industries not only can earn profits but also can raise competitive advantage. As the automobile industry is the benchmark of applying lean production nowadays, we will discuss the procedures, meanings and conditions of applying lean production in successful cases. Furthermore, we will also apply the successful experiences to variable unit-load production. By analyzing those successful experiences, we can design an exclusive and variable lean production system in unit-load production. We select the fishing nets production as a case in this study and in this research we use simulation methods as tools, and combine Taguchi method with technique for preference by similarity to ideal solution to find optimum solution. We also generalize the differences and possible reasons from a collection of experiments to plan the improvement directions of following strategies and use them as basis of policy decision. We also propose to combine Womack’s lean thinking and Rother’s 7 guiding principles procedure in this paper to apply the lean pull strategy and leveling scheduling into cases. The lean production procedure begins from defining value, addressing the adequate improvement time through the current value stream mapping, obtain the optimal solutions by using simulation optimization, and drawing the future value stream mapping as an implement of improved alternative. We implement the proposed procedure to a real-world fishing nets production process. After we compared current-state map and future-state map, the results indicate the improvement could reduce the average cycle time from 9.45 days to 2.07days as well as the work in process could reduce 84.73% without any extra investment or facilities shifting. As a result, we can have a further plan of increasing the capacity of bottleneck workstation and fulfill the spirit of “There is always a better way” completely. |
| Databáze: | Networked Digital Library of Theses & Dissertations |
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