Now that the production of many kinds with small-lot is required, the issue of loss due to equipment setup at the time of product change was also introduced in the previous Tech Magazine.
As one of the methods to reduce the loss due to the setup procedure, we introduced to set up "assignment of parts", that is, the assignment of machining processes in charge of equipment, but in fact it is possible to limit the allocation of equipment. However, there are some cases that you cannot do.
In this time, considering the case of creating a plan that minimizes set-up loss as much as possible while deciding the production plan without limiting the allocation of equipment.
1. Creating a Model
First of all, we will create a process to produce multiple products in the model we introduced last time (The 13th: Let's decide the conditions of work!)
As another production process of the product, consider the following process.
Here, in the process where [worker] is "○", it means that one worker implementing the processing is necessary.
This is expressed in GD.findi as follows.
The setup for switching from product A to product B and the setup for switching from product B to product A are as follows.
In addition, we assign "Team" for assignment of product B in station activity.
2. Setting up Production Plan
First, we set up the input plans for products produced in this production model as follows.
Let's see the simulation results with this setting.
Looking at the material flow, you can see that setups at the processing plant 1 and the processing plant 2 occur frequently.
3. Change of Production Plan
Generally, it is thought that increasing the production lot will reduce the number of setups and increase the production capacity.
The lot size is formulated taking into account the delivery schedule and delivering plan of the product, but here we will see the simulation results by increasing the number to be introduced in the input plan.
For example, let's set the number of input plans to be set to 10 for each product A (from 5), and for product B to be inserted to 20 for each (from 10).
The result is as follows.
As can be seen from the simulation results, it can be seen that by increasing the lot size, the number of occurrences of setup can be reduced and the production capacity is improved by the reduction of the loss.
As mention above, production plans are generally formulated taking various factors into consideration, but it is possible to measure the "loss due to set-up during production of multiple products" as one of the factors by utilizing GD.findi.
With the other constraints taking into consideration, it is possible to make a plan while comparing the results by performing the same situation when deciding the size of the appropriate lot.
For more details regarding GD.findi, please find the webpage or contact GD.findi email address as below.
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