Modelling and production configuration optimization for an assembly shop

Abstract

Flexible production is able to respond to a changing production system. To efficiently optimize a changed production layout and configuration, a modelling and optimization method based on discrete event simulation (DES) was proposed. A mathematical optimization model of the workshop layout was formulated and solved using a genetic algorithm (GA). In addition, a general modelling method for workshop logistics processes using DES was proposed to efficiently develop a simulation model of the complex production processes. Moreover, the simulation model of the entire production process was constructed using the Plant Simulation software package, and more production factors were considered and optimized. After the optimization process, the logistics volume decreased by 63.5%, and the throughput increased by 42.0%. Additionally, the production process was optimized, and the optimal equipment allocation, worker allocation, buffer allocation, and logistics vehicle allocation were determined. Our work can provide decision guidance and simulation validation for workshop planning.