Complex Assembly Line Production Simulation Modeling considering Robots Failure and Operator cycle times

摘要

This research paper demonstrates how to develop Simulation Model for a complex automotive assembly line process which consists of about 13 assembly stations, 80 robots, 6 conveyors and 7 manual operator load stations. In this paper, a simulation model was developed for the above assembly process; the results were verified and validated. The simulation modeling also incorporated the "what-if' scenario effects of the robots failure and operator cycle times on production. The simulation model was run for various scenarios using Arena modeling software. The findings were analysed using DOE and improvement ideas were presented to increase production. The general tendency in the plant to improve production is to buy more equipment. But, more machines also require more maintenance due to machine breakdowns. It is very interesting to see how the robots failure and the operator cycle time affect the production.