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Customized Mixed Model Stochastic Assembly Line Modelling Using Simulink

Assembly lines have been critical to the successful operation of manufacturing plants over the years. This is mainly attributed to the ability of assembly lines to adjust to the needs of the industry at any given time. Therefore, it is imperative that assembly lines adjust to the era of smart manufacturing commonly termed as Industry 4.0. This latest trend in industrial revolution has many facets, changing the way products are designed, manufactured and delivered. One such standout feature of Industry 4.0, is how it has changed the way products are ordered. Industries are moving from a conventional make-to-stock approach to a maketo-order approach. This paper looks at how a customized ordering system can be modelled for a mixed model assembly line. The research is based on a case study using a water bottling plant which can bottle 500 ml and 750 ml bottles. The economic viability and a preliminary model for the project was done and documented previously. This paper is structured such that it initially provides an introduction to the research. Secondly, it provides an overview of the previous model and its limitations. Thirdly, the paper shows how the current model has been developed in Simulink to introduce customized ordering. Finally, the results obtained from the simulation are shown. The primary aim of this research is to develop a Simulink model for customizing the input of a water bottling plant. This model can then be used to optimize the time to manufacture water bottles and contribute to the broader research area of Mixed Model Stochastic Assembly Line Balancing.