Tam zamanında üretime yönelik, imalat sistemlerinin benzetim ile tasarımı
A Simulation model for production system design to the way of JIT
- Tez No: 21705
- Danışmanlar: PROF. DR. ATAÇ SOYSAL
- Tez Türü: Yüksek Lisans
- Konular: Endüstri ve Endüstri Mühendisliği, Industrial and Industrial Engineering
- Anahtar Kelimeler: Belirtilmemiş.
- Yıl: 1992
- Dil: Türkçe
- Üniversite: İstanbul Teknik Üniversitesi
- Enstitü: Fen Bilimleri Enstitüsü
- Ana Bilim Dalı: Belirtilmemiş.
- Bilim Dalı: Belirtilmemiş.
- Sayfa Sayısı: 92
Özet
The effîcent methods employed by major Japanese manufacturing concerns -particularly their automobile industry- continue to create great interest. These are just- in-time methods, where each step of the manufacturing process occurs just-in-time for the next step to begin- but not too soon or there is unnecessary inventory buildup between manufacturing steps, and not too late or there is idle time at some work stations. These are also called stockless- production and zero-inventory methods, referring to little or no buildup of work-in-process inventory. In ideal just-in-time manufacturing systems, all work stations are balanced so each worker has approximately the same load. While this is also the goal of traditional assembly-line balancing, just-in-time systems are so refined that, when necessary, mechinery and products are redesigned to achieve a balanced line. Workers process one part at a time. When complete, it is paased to the next worker who has just completed another single part and just passed it to the next work station. And so no. This differs from how mass-production systems are traditionally used. Historically, little has been done to modify machines so work stations are in balance. Rather, work-in-process is used as a buffer to correct such imbalances. Consequently, work centers are not balanced and work-in-process is high. In OPT, production is not scheduled with either a '.'push“ or ”pull“ technique, but on a ”bottleneck" basis. The bottleneck areas in a facility are analyzed and then emphasized. Production is planned so that the bottleneck work centers will be utilized to the maximum and all other departments which are not bottlenecks will be planned to keep the bottleneck departments working at full production at all times. In OPT; schedules are not as time consuming to set up, schedules do not require as much data, less computer processing capability is required, quick schedules allow for the quick modification of the schedules and therefore more flexibility in the schedules, schedule changes occur in a few hours rather than days, quick schedule development allows for simulation to be used in the scheduleing process, bottlenecks in the production process are specifically defined, inprovements are easily made on the bottlenecks because of their clear definition, simulation can be used to test variations in plant output (product mix or load) and how this will effect the plant load, and actual manufacturing resources (finite resources) are taken into account.
Özet (Çeviri)
SUMMARY A SIMULATION MODEL FOR PRODÜCTION SYSTEM DESIGN TO THE WAY OF JÎT The first Chapter is introduction to subject. in This chapter, flexibilty, productivity and relationship of them are defined. in the second chapter,The new production technologies are explained. For example; flexible manufacturing systems, computer integrated manufacturing systems. Chapter three describes, the production control techniques. Production control systems for a multi-stage production process can be classified into two types, namely push and pul! systems. Most of manufacturers create production scheduleson the assumption that they can be executed. If work is completed as scheduled, it is sent from a work centre to the next location at which parts are scheduled for use. This is 'push system' : make the parts and send them to where they are next needed, ör to inventory, thus pushing material through production according to schedule. in this system the function of production control is to keep production on schedule. Most manufacturers have deviations between what was scheduled and what actually occurs, so production control consists of recognizing these deviations and taking action. There is only limited amount of inventory at each stage. A succeeding process orders and withdraws parts from to storage of the preceding process“, only at the rate and at the time it has used the items. This is called pul! type production order system, ör pul! system in brief. Material requirements planning (MRP) is a computerized information system designed to handle ordering and scheduling of dependent demand inventories (i.e., raw materials, subassemblies, parts). The material requirements planning system is a logical sequence in which the component parts of assembled end products are identified (this indicates what to order). The component parts are then aggegated (this indicates how much to order) according to their due dates (this indicates when to order). The identification of the component parts is sometimes called the 'explosion' ofthe end product. viiThe effîcent methods employed by major Japanese manufacturing concerns -particularly their automobile industry- continue to create great interest. These are just- in-time methods, where each step of the manufacturing process occurs just-in-time for the next step to begin- but not too soon or there is unnecessary inventory buildup between manufacturing steps, and not too late or there is idle time at some work stations. These are also called stockless- production and zero-inventory methods, referring to little or no buildup of work-in-process inventory. In ideal just-in-time manufacturing systems, all work stations are balanced so each worker has approximately the same load. While this is also the goal of traditional assembly-line balancing, just-in-time systems are so refined that, when necessary, mechinery and products are redesigned to achieve a balanced line. Workers process one part at a time. When complete, it is paased to the next worker who has just completed another single part and just passed it to the next work station. And so no. This differs from how mass-production systems are traditionally used. Historically, little has been done to modify machines so work stations are in balance. Rather, work-in-process is used as a buffer to correct such imbalances. Consequently, work centers are not balanced and work-in-process is high. In OPT, production is not scheduled with either a '.'push”or“pull”technique, but on a“bottleneck”basis. The bottleneck areas in a facility are analyzed and then emphasized. Production is planned so that the bottleneck work centers will be utilized to the maximum and all other departments which are not bottlenecks will be planned to keep the bottleneck departments working at full production at all times. In OPT; schedules are not as time consuming to set up, schedules do not require as much data, less computer processing capability is required, quick schedules allow for the quick modification of the schedules and therefore more flexibility in the schedules, schedule changes occur in a few hours rather than days, quick schedule development allows for simulation to be used in the scheduleing process, bottlenecks in the production process are specifically defined, inprovements are easily made on the bottlenecks because of their clear definition, simulation can be used to test variations in plant output (product mix or load) and how this will effect the plant load, and actual manufacturing resources (finite resources) are taken into account.In the fourth chapter, the Simulatiom is explained. Model is a simplified or idealized description of a system, situation, or process, often in mathematical terms, devised to facilitate calculations and predictions. Simulation is the technique of imitating the behaviour of some situation or system (economic, military, mechanical, etc.) by means of an analogous situation, model or apparatus, either to gain information more conveniently or to train personnel. Simulation is the technique of building an abstract, logical model of a system, which describes the internal behaviour of its components and their interactions, including stochastic variability. It enables the behaviour of the system as a whole to be predicted so that we may gain information about the system, or trin personnel in its operation, without disrupting the real system, because experimenting with the real system is impossible or uneconomic. Within the thesis, the workshop runs for a large scale batch production system is modeled. The workshop is thought to be converted and implemented into three different systems The flow of workpieces in workshop is as follows. Firstly the batch starts to enter the system with a certain probability density function and they get loaded to machine tools with lowest queue. The batches undergo the operation cycle time of batches are founded by summing the operation, discarted parts operation, rework, set up, load-unload and inspection times. While the queues, in the systems of clasic machine tool system and CNC tools system, are formed beside tools, in FMS they are formed beside load-unload station and carried by transporters. The case study is applied for a workshop called krank shaft line in a factory produces water pumps. All the data are provided from the company planning department and demonstrated in the last section of the thesis. XTThe effîcent methods employed by major Japanese manufacturing concerns -particularly their automobile industry- continue to create great interest. These are just- in-time methods, where each step of the manufacturing process occurs just-in-time for the next step to begin- but not too soon or there is unnecessary inventory buildup between manufacturing steps, and not too late or there is idle time at some work stations. These are also called stockless- production and zero-inventory methods, referring to little or no buildup of work-in-process inventory. In ideal just-in-time manufacturing systems, all work stations are balanced so each worker has approximately the same load. While this is also the goal of traditional assembly-line balancing, just-in-time systems are so refined that, when necessary, mechinery and products are redesigned to achieve a balanced line. Workers process one part at a time. When complete, it is paased to the next worker who has just completed another single part and just passed it to the next work station. And so no. This differs from how mass-production systems are traditionally used. Historically, little has been done to modify machines so work stations are in balance. Rather, work-in-process is used as a buffer to correct such imbalances. Consequently, work centers are not balanced and work-in-process is high. In OPT, production is not scheduled with either a '.'push“ or ”pull“ technique, but on a ”bottleneck" basis. The bottleneck areas in a facility are analyzed and then emphasized. Production is planned so that the bottleneck work centers will be utilized to the maximum and all other departments which are not bottlenecks will be planned to keep the bottleneck departments working at full production at all times. In OPT; schedules are not as time consuming to set up, schedules do not require as much data, less computer processing capability is required, quick schedules allow for the quick modification of the schedules and therefore more flexibility in the schedules, schedule changes occur in a few hours rather than days, quick schedule development allows for simulation to be used in the scheduleing process, bottlenecks in the production process are specifically defined, inprovements are easily made on the bottlenecks because of their clear definition, simulation can be used to test variations in plant output (product mix or load) and how this will effect the plant load, and actual manufacturing resources (finite resources) are taken into account.In the fourth chapter, the Simulatiom is explained. Model is a simplified or idealized description of a system, situation, or process, often in mathematical terms, devised to facilitate calculations and predictions. Simulation is the technique of imitating the behaviour of some situation or system (economic, military, mechanical, etc.) by means of an analogous situation, model or apparatus, either to gain information more conveniently or to train personnel. Simulation is the technique of building an abstract, logical model of a system, which describes the internal behaviour of its components and their interactions, including stochastic variability. It enables the behaviour of the system as a whole to be predicted so that we may gain information about the system, or trin personnel in its operation, without disrupting the real system, because experimenting with the real system is impossible or uneconomic. Within the thesis, the workshop runs for a large scale batch production system is modeled. The workshop is thought to be converted and implemented into three different systems The flow of workpieces in workshop is as follows. Firstly the batch starts to enter the system with a certain probability density function and they get loaded to machine tools with lowest queue. The batches undergo the operation cycle time of batches are founded by summing the operation, discarted parts operation, rework, set up, load-unload and inspection times. While the queues, in the systems of clasic machine tool system and CNC tools system, are formed beside tools, in FMS they are formed beside load-unload station and carried by transporters. The case study is applied for a workshop called krank shaft line in a factory produces water pumps. All the data are provided from the company planning department and demonstrated in the last section of the thesis. XT
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