مدل داده محور شبیه سازی عمومی برای حمل و مونتاژ تعبیه شده خطوط تولید

Simulation has been used to evaluate various aspects of manufacturing systems. However, building a simulation model of a manufacturing system is time-consuming and error-prone because of the complexity of the systems. This paper introduces a generic simulation modeling framework to reduce the simulation model build time. The framework consists of layout modeling software and a data-driven generic simulation model. The generic simulation model was developed considering the processing as well as the logistics aspects of assembly manufacturing systems. The framework can be used to quickly develop an integrated simulation model of the production schedule, operation processes and logistics of a system. The framework was validated by developing simulation models of cellular and conveyor manufacturing systems.

Simulations have been used for various purposes in manufacturing. They are used for strategic capacity planning, automation systems design, manufacturing process validation, and evaluation of various manufacturing execution scenarios. They can be used to analyze how system performance is affected by the layout configuration, the number of material handling resources used, the resource operating policies, and the usage of different types of material handling systems (MHS). A typical example simulation study can be found in Mackulak and Savory (2001). However, a simulation model that encapsulates the details of a manufacturing system is very time-consuming to build and debug. Engineers and researchers typically build simulation models with their own style based on their own experiences, without consideration of reusability, and the models are sometimes error-prone. The severe competitive pressures in the manufacturing industry require much quicker turnarounds for simulation projects. In order to cope with this challenge, we recently proposed a data-driven generic simulation modeling framework for semiconductor fabrication lines (Kim et al., 2009). As Mackulak, Lawrence, and Colvin (1998) stated, using a generic simulation model has two primary advantages: quick model construction and the reuse of more accurate (bug-free) models. This paper applies the framework to assembly manufacturing lines with development of a data-driven generic simulation model for the lines. The generic model described in this paper was developed with in-depth consideration of the logistics aspects, i.e., the material flows. The data representation scheme for the generic simulation model and the logical flow of the model are presented. The remainder of this paper is organized as follows: A brief literature review of the simulation program generator and generic simulation models is provided in Section 2. After our proposed generic modeling framework is briefly described in Section 3, the generic simulation model is presented for logistics-embedded assembly manufacturing lines in Section 4. Section 5 discusses the model verification and application of the proposed framework. Section 6 contains concluding remarks.

This paper reported the effort in the development of a generic simulation model for logistics-embedded assembly manufacturing lines, which consists of the layout modeling software called AutoLay and a generic simulation model called AutoLogic-Assembly. Using AutoLay, an accurate CAD physical layout can be easily converted into a simulation layout model. This feature can reduce the initial modeling time significantly. Even when there is no CAD layout data, AutoLogic-Assembly can be used if the resources, queues, flow paths, and control points are appropriately defined in the simulation model. For the generic model, we developed a data model considering the assembly operations as well as the logistics aspects, such as delivery resources and carts. The formats of the data model are comprehensive but easy to understand because they follow natural assembly procedures. The simulation engineers of Samsung Electronics Co. had no difficulty in using the data model. The generic model can be used to develop an integrated simulation model of production processes and material handling processes in a short period of time. Simplified simulation models and sets of layout data have been made to verify and validate the AutoLay and AutoLogic-Assembly. In addition, two full simulation models developed by a traditional approach were modeled using the proposed approach. The traditional approach required about 2 weeks each to build the models, while the proposed approach had model building time of about 1 day each. Even when the generic model requires extension, the new logic can be added or the simulation model be modified easily. The proposed framework and the software are now being used by the simulation analysts of Samsung Electronics Co.