Problems of System Dynamics model development for complex product manufacturing process

Abstract

Computer simulations are applied in enterprises for different purposes. They are used to support decision making at different levels of management. System Dynamics (SD) method is successfully used to model and simulate complex systems (including enterprises and manufacturing lines), but its applications are limited mostly to the policy and strategy level. This is due to the fact that SD approach assumes a low level of details and perceiving the system as a whole, and on the other hand, the reason may be the lack of examples of modelling manufacturing lines and workstations, at a higher level of detail. Based on a case study of a complex manufacturing system, this work presents examples of SD models of workstations and manufacturing line elements. Problems that were discussed in the frame of this paper are: process discretization, information flow with the use of kanban cards, processing of various components in one process, work of many employees at one workstation and assembly kit completion. The presented work may encourage researchers to use SD to model and simulate manufacturing lines at the operational level, and the presented solutions will be used in industrial practice to analyse and improve production systems.