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Using A Simulation To Generate The Data To Balance An Assembly Line

Coors Brewing Company's 16 ounce can production line was generating over $2 million annually in scrap production. Flow scrap is generated when a machine stops because it is working faster or slower than its adjacent machines. The production line flow problem was that the machines were not working together in such a way to keep the flow of cans constant from the start to the finish of the line. This work demonstrates an analysis process that minimizes the generation of flow scrap in the context of the assembly line balancing problem. The process is 1) develop a verified and validated simulation model; 2) design an experiment to run using the simulation and to collect output data from the simulation; 3) using the experimental design to determine values of the independent variables and the output data as the dependent variable, develop a metamodel; and 4) optimize the metamodel using response surface methodology. Applying this process to the Coors problem generated an annual savings of $1.87 million in 1996 dollars. 1 GENERAL IMPORTANCE Many manufacturing systems today are automatic, and products are created at an amazing rate. The assembly line allows these products to be produced by a small number of people. In many instances the human factor is nothing more than a maintenance function, fixing problems when they arise. Otherwise, the machines run by themselves. These machines do not have the physical limitations that humans do and, therefore, can operate at significantly higher speeds than a human. The goal of any assembly line is to continuously generate throughput by keeping the flow of materials constant from start to finish. Generally, the back of the assembly line pulls processes in the front. More specifically, each machine pulls production from the machine immediately preceding itself. In some manufacturing situations, if a machine runs too fast or too slow, it will cause other machines to stop. When these machines stop, objects currently being