Evaluation of batching and layout on the performance of flexible manufacturing system

Abstract

Flexible manufacturing system (FMS) is one of the solutions that enables any manufacturing system to withstand changing requirements of the market. An FMS consists of different automated workstations, material handling devices, and storage systems, all of which work under computer control. In the present work, analysis and modeling of a real problem has been considered for performance improvement. Modeling is done for analyzing the performance of an existing model, to propose a new layout for the system. Effect of factors like part mix, layout type, and batching condition, on the system performance in terms of productivity, system utilization rate, and cycle time is analyzed. The work includes simulation study along with Taguchi’s experimental design framework for studying how different factors with varying levels affect system performance. ProModel software is used for simulating existing and proposed models of the manufacturing firm. Further, analysis of variance (ANOVA) is employed for finding the most important factor that affects system performance. Proposed methodology helps in determining best factor-level combination for each performance parameter. The results show that the system performs well with the implementation of loop layout having many numbers of batches. Towards the end, the scope of further is highlighted.

This is a preview of subscription content, log in to check access.

References

  1. 1.

    Arshad M, Milana M, Khan MK (2016) Scheduling of three layouts using four scheduling rules. Proceedings-International Conference on Industrial Engineering and Operations Management, Kula Lumpur, Malaysia, March 8–10: 2539–2548

  2. 2.

    Dosdogru AT, Gocken M, Geyik F (2015) Integration of genetic algorithm and Monte Carlo to analyze the effect of routing flexibility. Int J Adv Manuf Technol 81:1379–1389

    Article  Google Scholar 

  3. 3.

    Florescu A, Baarabas S, Sarbu F (2017) Operational parameters estimation for a flexible manufacturing system: a case study. MATEC Web of conference 112: 01–06

  4. 4.

    Gyulai D, Pfeiffer A, Monostori L (2016) Robust production planning and control for multi-stage systems with flexible final assembly lines. Int J Prod Res 55(13):3657–3673

    Article  Google Scholar 

  5. 5.

    He Y, Stecke KE, Smith ML (2016) Robot and machine scheduling with state-dependent part input sequencing in flexible manufacturing systems. Int J Prod Res 54(22):6736–6746

    Article  Google Scholar 

  6. 6.

    Yadav A, Jayswal SC (2018) Modelling of flexible manufacturing system: a review. Int J Prod Res 56(7):2464–2487

    Article  Google Scholar 

  7. 7.

    Yang T, Peters BA, Tu M (2005) Layout design for flexible manufacturing system considering single-loop directional flow patterns. Eur J Oper Res 164:440–455

    Article  MATH  Google Scholar 

  8. 8.

    Groover MP (2007) Automation, production systems, and computer integrated manufacturing, 3rd edn. Prentice Hall Press Upper Saddle River, NJ

  9. 9.

    Browne J, Dubois D, Rathmill K, Seth SP, Stecke KE (1984) Classification of flexible manufacturing systems. FMS Mag 2:114–117

    Google Scholar 

  10. 10.

    Sethi AK, Sethi SP (1990) Flexibility in manufacturing: a survey. Int J Flex Manuf Syst Serv Oper Manag 2(4): 289–328

  11. 11.

    Chan FTS (2001) The effects of routing flexibility on a flexible manufacturing system. Int J Comput Integr Manuf 14(5):431–445

    Article  Google Scholar 

  12. 12.

    Joseph A, Sridharan R (2011) Evaluation of routing flexibility of a flexible manufacturing system using simulation modelling and analysis. Int J Adv Manuf Technol 56:273–289

    Article  Google Scholar 

  13. 13.

    Francas D, Lohndorf N, Minner S (2011) Machine and labor flexibility in manufacturing network. Int J Prod Econ 131:165–174

    Article  Google Scholar 

  14. 14.

    Verma A, Mishra N, Singh RK (2011) Effect of machine flexibility on the performance of FMS subjected to frequent breakdowns. Int J Serv Oper Informatics 6(1–2):45–70

    Google Scholar 

  15. 15.

    Singholi A, Ali M, Sharma C (2013) Evaluating the effect of machine and routing flexibility on flexible manufacturing system performance. Int J Serv Oper Manag 16(2):240–261

    Google Scholar 

  16. 16.

    Singholi A (2015) Impact of manufacturing flexibility and pallets on buffer delay in flexible manufacturing systems. Int J Eng Manag Econ 5(3):308–330

    Article  Google Scholar 

  17. 17.

    Potts CN, Whitehead JD (2001) Workload balancing and loop layout in the design of a flexible manufacturing system. Eur J Oper Res 129:326–336

    Article  MATH  Google Scholar 

  18. 18.

    Srinivas C, Ramji K, Satyanarayana B, Ravela N (2013) Simulation based layout design of large sized multi-row flexible manufacturing system. J Eng Arch 1(1):34–44

    Google Scholar 

  19. 19.

    Gingu EI, Zapciu M (2014) Improving layout and workload of manufacturing system using Delmia Quest simulation and inventory approach. Int J Innov Res Adv Eng 1(6):52–61

    Google Scholar 

  20. 20.

    Shivhare M, Bansal S (2014) Layout optimization in flexible manufacturing system using particle swarm optimization in Matlab. Int J Soft Eng App 8(7):55–64

    Google Scholar 

  21. 21.

    Lashkari RS, Dutta SP, Padhye AM (1987) A new formulation of operation allocation problem in flexible manufacturing systems: mathematical modelling and computational experience. Int J Prod Res 25:1267–1283

    Article  MATH  Google Scholar 

  22. 22.

    Tiwari MK, Vidyarthi NK (2000) Solving machine loading problems in a flexible manufacturing system using a genetic algorithm based heuristic approach. Int J Prod Res 38(14):3357–3384

    Article  MATH  Google Scholar 

  23. 23.

    Suresh NC (1990) Toward an integrated evaluation of flexible automation investment. Int J Prod Res 28:1657–1672

    Article  Google Scholar 

  24. 24.

    Yao DD, Buzacott JA (1985) Modelling the performance of flexible manufacturing systems. Int J Prod Res 23(5):945–959

    Article  MATH  Google Scholar 

  25. 25.

    Matsui M, Uehara S, Jingsong M (2001) Performance evaluation of flexible manufacturing systems with finite local buffers: fixed and dynamic routings. Int J Flex Manuf Syst 13:405–424

    Article  Google Scholar 

  26. 26.

    Chan FTS (2003) Effects of dispatching and routeing decisions on the performance of a flexible manufacturing system. Int J Adv Manuf Technol 21:328–338

    Article  Google Scholar 

  27. 27.

    Binghai Z, Lifeng X, Yongshang C (2004) A heuristic algorithm to batching and loading problems in a flexible manufacturing system. Int J Adv Manuf Technol 23:903–908

    Article  Google Scholar 

  28. 28.

    Caprihan R, Wadhwa S (2005) Scheduling of FMS with information delays: a simulation study. Int J Flex Manuf Syst 17:39–65

    Article  MATH  Google Scholar 

  29. 29.

    Chan FTS, Bhagwat R, Wadhwa S (2008) Comparative performance analysis of a flexible manufacturing system (FMS): a review-period-based control. Int J Prod Res 46(1):1–24

    Article  MATH  Google Scholar 

  30. 30.

    Wahab MIM, Stoyan SJ (2008) A dynamic approach to measure machine and routing flexibilities of manufacturing systems. Int J Prod Econ 113(2):895–913

    Article  Google Scholar 

  31. 31.

    Ahkioon S, Bulgak AA, Bektas T (2009) Cellular manufacturing systems design with routing flexibility, machine procurement, production planning and dynamic system reconfiguration. Int J Prod Res 47(6):1573–1600

    Article  MATH  Google Scholar 

  32. 32.

    Kumar RMS, Asokan P, Kumanan S (2008) Design of loop layout in flexible manufacturing system using non-traditional optimization technique. Int J Adv Manuf Technol 38:594–599

    Article  Google Scholar 

  33. 33.

    Kumar MVS, Janardhana R, Rao CSP (2011) Simultaneous scheduling of machines and vehicles in an FMS environment with alternative routing. Int J Adv Manuf Technol 53:339–3511

    Article  Google Scholar 

  34. 34.

    Ali M, Wadhwa S (2010) The effect of routing flexibility on a flexible system of integrated manufacturing. Int J Prod Res 48(19):5691–5709

    Article  Google Scholar 

  35. 35.

    Barad M (2013) Flexibility development - a personal retrospective. Int J Prod Res 51(23–24):6803–6816

    Article  Google Scholar 

  36. 36.

    Jain V, Raj T (2016) Modeling and analysis of FMS performance variables by ISM, SEM and GTMA approach. Int J Prod Econ 171:84–96

    Article  Google Scholar 

  37. 37.

    Kumar R (2016) Simulation of manufacturing system at different part mix ratio and routing flexibility. Gl J Ent Info Sys 8(1):09–14

    Google Scholar 

  38. 38.

    Rybicka J, Tiwari A, Enticott S (2016) Testing a flexible manufacturing system facility production capacity through discrete event simulation: automotive case study. Int J Mech Aero Ind Mechatronice Manuf Eng 10(4):668–672

    Google Scholar 

  39. 39.

    Mahmood K, Karaulova T, Otto T, Shevtshenko E (2017) Performance analysis of a flexible manufacturing system performance. The 50th CIRP conference on manufacturing systems, Procedia CIRP-63: 424–429

  40. 40.

    Phadke SM (1989) Quality engineering using robust design. Prentice Hall, Englewood Cliffs

    Google Scholar 

  41. 41.

    Solberg JJ (1981) Capacity planning with stochastic workflow model. AIIE Trans 13(2):116–122

    Article  Google Scholar 

  42. 42.

    Mejabi O (1988) Modeling in flexible manufacturing system design. Ph.D Dissertation, Lehigh University, Bethlehem, Pennsylvania

Download references

Acknowledgements

The authors acknowledge the anonymous referee of this paper for his or her valuable suggestions, which have helped to improve the quality of this paper.

Author information

Affiliations

Authors

Corresponding author

Correspondence to Anupma Yadav.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Yadav, A., Jayswal, S.C. Evaluation of batching and layout on the performance of flexible manufacturing system. Int J Adv Manuf Technol 101, 1435–1449 (2019). https://doi.org/10.1007/s00170-018-2999-1

Download citation

Keywords

  • Flexible manufacturing system
  • Simulation
  • Taguchi
  • ProModel
  • ANOVA
  • Modeling
  • Analysis
  • Part mix flexibility
  • Layout
  • Batch
  • Conveyor
  • Production rate