Modelling Bottleneck Factors In A Production Line Using Hybrid Approach
A bottleneck can occur in almost all business organizations, either services or manufacturing operations. In manufacturing sector, bottleneck normally occurs due to repetitive failures in the flow of production system. Besides that, there are several factors that can cause bottleneck events in th...
Saved in:
| Main Author: | |
|---|---|
| Format: | Thesis |
| Language: | English |
| Published: |
2016
|
| Subjects: | |
| Online Access: | http://eprints.usm.my/46921/1/Modelling%20Bottleneck%20Factors%20In%20A%20Production%20Line%20Using%20Hybrid%20Approach.pdf |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| Summary: | A bottleneck can occur in almost all business organizations, either services or
manufacturing operations. In manufacturing sector, bottleneck normally occurs due to
repetitive failures in the flow of production system. Besides that, there are several
factors that can cause bottleneck events in the production line, such as long waiting time,
huge backlog and high stress level. These bottleneck factors can reduce the throughput
rate in the production line and negatively affect the production costs. Therefore, it
should be tackled for a high production system performance and a smooth flow of
products. Because of that, there is a need for the manufacturers to find ways in managing
the bottleneck factors. In general, bottlenecks can be caused by tangible and intangible
factors. However, the intangible factors have received less attention by the previous
researchers. Most previous works had focused on tangible factor such as number of
throughput but lack in intangible such as on workers stress level. Thus, this research
investigates the intangible factors which emphasizes on human factor particularly in
understanding the effect of absenteeism in the production line. In addition, this study
also identifies causes of bottleneck in illustrating the relationship between human factors
and production line. Absenteeism refers to a situation when the available manpower is
less than the number of manpower needed on the production line. This human factor
plays an important role in determining the production rate. In this thesis, a hybrid
simulation model is used to analyse the absenteeism problem in an aircraft composite
manufacturing by integrating a Discrete Event Simulation (DES) and a System
Dynamics (SD) models which namely as Hybrid Simulation Based Bottleneck
Management (HSBBM). To analyse the effect of absenteeism, the amount of
throughput, waiting time, work in process (WIP) and cycle time are analysed in various
scenarios of production planning. The result shows the number of absentees at
production line increase the workload to the available worker and gives effect to the
production rate. By considering the absenteeism, the number of throughput decrease
12.67% compared to the production plan indicating that the hybrid model is able to
represent more realistic situation when involving human factor. In conclusion, the
developed hybrid model can be used to visualise and quantify the impacts of human
behaviour that lead to bottlenecks and able to assist the management to generate more
relevant production plan. |
|---|