Analysis in manufacturing systems simulation – a case-study

A case study of the transition of an electronics assembly manufacturing system from a traditional push production control system to a just in time (pull control system) is presented. Emphasis is on the unique simulation analysis aspects of the case study. The experimental design follows a dynamic programming formulation, representing the system transition through stages with the states at each stage representing combinations of stage-specific improvement possibilities and process control parameter values. Relationships between the primary performance measure, run time for a batch, and other performance measures are developed to identify process control variables and opportunities for system improvement. Actual production control data are employed for validation of system standard values, estimation of model input parameter values, and comparison with simulation results for validation purposes.