The development and application of a simulation approach to advanced manufacturing systems planning

摘要

In the competitive field of metalworking industry, the planningof manufacturing systems so as to maximise their performance iscrucial. The relatively new field of Flexible ManufacturingSystems presents a new set of planning challenges to theproduction engineer. This is due to the integrated nature of thethese systems and the resultant effects upon their performance.This thesis presents a structured approach to the planning ofmaterials flow within these systems and develops it by theanalysis of several proposed manufacturing systems. The approachis based upon the use of mathematical and discrete eventsimulation techniques.The thesis gives the background to the need for a structuredapproach, investigates the parallel development of simulationlanguages and related techniques as applied to manufacturingfacilities planning; and of the Flexible Manufacturing Systemsthemselves. The approach is then detailed and some specifictypes of planning tool are identified as suitable for use ateach project stage. The effects upon the system of theintegration of separate units, especially in low work inprogress environments, are discussed in some detail.The methodology developed is then used in the context of threeprojects, specifically developing the theme of automated toolhandling and the requirements that it places upon other aspectsof a manufacturing system. The projects cover the analysis ofpooling strategies, a key factor in determining tool magazinesizes and handling capacity/frequency demands; an academicanalysis of a system with both component and tool handlingsystems; and an advanced Flexible Manufacturing System, alsowith both automated component and tool handling, which iscurrently being installed.Conclusions are presented at each stage, and these are drawntogether to form a foundation for the planning of materials flowwithin Flexible Manufacturing Systems in general. Finally,suggestions are made for future work to develop the analysis.