Parallel batching dominated production line: A simulation study of capacity and cost sensitivity

Date

2012

Authors

Syed, Firasath Ahmed

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Abstract

Parallel batching is the process where similar parts are grouped together and go through the same manufacturing process simultaneously, such as heat treatment, tanning, etc. This helps in reducing the processing time. But this also increases the time to form a batch for processing and the wait time after the process. Large batch sizes lead to long wait times and long queues. On the other hand, small batch sizes cause unnecessary delay for the remaining jobs which would otherwise have been a part of the batch. Therefore it is crucial to decide the number of jobs that go into a batch to maximize the benefit of parallel batching.

This thesis proposes an optimization procedure which helps in finding the most profitable input batch size of a complex manufacturing system dominated by a parallel batching process. Arena simulation software is used with which the system under study is modeled and simulated and the results obtained from simulation are used for optimization of the profit obtained. Profit is calculated as a function of input batch size entering into the system. Hence by varying the input batch size to the system, simulation models are developed, and the profit for each batch size is found and compared. The batch size at which maximum profit is achieved is the best batch size to the system which results in maximum profit. The effect of customer demand on the profit is studied by creating two simulation models having different customer demand pattern.

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Keywords

Manufacturing Engineering, Optimization, Parallel Batching, Simulation with Arena

Citation

Department

Mechanical Engineering