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Simulation analysis of processing complexity and production variety in automated manufacturing system

In this paper, a simulation model for a manufacturing system is developed using Rockwell Software (ARENA 15.7-Platform) running production processes of multi-options product (MOP). There are different types of processes in the system which is either automated or non-automated making the manufacturing system as a partially automated system. Currently four types of products are planning into the productions which are practically coded OP1, OP2, OP3, and OP4. Because of the shortage in capacity of the non-automated processes compare to the automated, and adopting a fully automated production process is not applicable in the system causing OP1 directly goes out of the system to be manufactured later utilizing another plant. The objective of the work is to identify the resources needed to stabilize the system and run the entire product variety utilizing the current plant resources. Therefore, the problem is overcoming trade-offs between two solution scenarios; to find an optimal setup of automated processes that realizes the highest possible level of throughput and working effectively with the capacity of non-automated ones, and find the required setup of the resources running the system responsively. Different allowable cycles of processing time are examined to investigate the impact on the system throughput along with simulation experiments. Results show that there are many of opportunities to improve the MOP production processes using simulation methodology along with low investments. The analysis shows that there is no evidence that necessitates adoption of the full automation to the system improving the production. In other words, the automated section of the system involves the modifiable processes for optimizing the utilization of system resources.