Aggregate simulation modeling with application to setting the CONWIP limit in a HMLV manufacturing cell

Abstract

Concepts for aggregate modeling and simulation are presented and applied for the setting of the parameters of a CONWIP flow control system within the steel products cell at Grand Rapids Chair, a high-mix, low-volume manufacturing environment. Aggregation was accomplished by combining the over 100 types of products into one. This resulted in a single arrival process, routing modeled as random movement through workstations, and a single operation time distribution for each production operation. Aggregation reduced the effort required for model development, data analysis, validation, and simulation. The CONWIP control was shown to be effective in managing the work-in-process. A CONWIP parameter of 50 resulted in an equivalent throughput to that achieved with no limit on work-in-process. Lead time can be reduced by approximately 20% by increasing the CONWIP parameter to 58.

Keywords

• Aggregate simulation modeling
• High-Mix
• Low-Volume Manufacturing
• CONWIP
• Production Flow
• Discrete-Event Simulation