A study of a kanban based assembly line feeding system through integration of simulation and particle swarm optimization

Abstract

With increase in differentiation and decreasing batch size of products, feeding the assembly line at regular intervals is considered to be a critical problem in today’s manufacturing sector. Yet no clear solution has been developed for this problem; therefore, the main focus of this research is to discuss the different aspects of line feeding, the latest trend in literature, and to propose an innovative method to support solving the problem. A discrete event simulation model is developed and a mathematical model based on particle swarm optimization is used to support the simulation. The hybrid model is finally applied to practical situations. Results show how different settings of kanban influence the performance of the assembly line feeding system. The biggest novelty item is certainly the recognition of the trade-off between kanban size and number of kanban and the importance of investigating its behaviour during the design of the system.