Assembly Line Modeling And Simulation Of Footwear Manufacturing (a Case Study On Ramsey Shoe Factory

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In today’s competitive global market, companies are mostly striving to strengthen themselves asrnmuch as possible in all competiveness dimensions of business. This demands for optimalrnproduction system which increases the overall productivity of the company. Survival of anyrnbusiness in today’s competitive market place depends mainly on response time, production cost,rnmarket price and flexibility of manufacturing. These things motivated continuous research inrnmodeling and performance evaluation of manufacturing systems. In parallel to this, differentrnsimulation software play a great role in designing a model of a real system and conductingrnexperiments with this model for the purpose of understanding the behavior of the system andrnevaluating various strategies and scenarios for the operating or manufacturing system. Since thernmajority of consumable and non consumable goods are manufactured on assembly line system;rnassembly line balancing problem is getting importance now a day. Footwear is one of the goodsrnwhich are manufactured on assembly line system. Hence, this thesis is concerned with thernmodeling and simulation of assembly line balancing of footwear manufacturing in Ramsey ShoernFactory. Within the production department this thesis is mainly concerned with the modeling andrnsimulation of the two assembly lines: Stitching and Lasting assembly line. To do so, Arenarnsimulation software is employed to model and measure performance of existing manufacturingrnsystems of both assembly lines. Based on the simulation model result of the existing system,rndifferent scenarios are proposed to solve observed problems of the existing manufacturingrnsystem. Problems that are identified in simulation model analysis were: Line balance efficiencyrnfor both assembly lines is low, Relatively high level of WIP is observed in some work station ofrnstitching assembly line, low production output with respect to the installed capacity, and thernoutput of stitching assembly line is significantly higher than that of the lasting assembly linernwhich causes WIP of different model shoes to be piled up in between the two assembly lines. Tornsolve these problems, five possible scenarios are developed. These are: Avoiding unnecessaryrnAssembly line modeling and simulation of footwear manufacturing 2011rnA case study on Ramsey shoe factory, AAiT (By Nahom M.) Page virnduplication resource from station with low capacity utilization, merging similar operations withrnlow resource utilization together and assign to one worker, increasing level of resource atrnstations with high WIP, changing working method, and combination of all the above alternatives.rnAmong the five developed scenarios, the last one, ‘Combination of all the above alternatives’rngives better performance of footwear manufacturing for the selected model shoe.

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Assembly Line Modeling And Simulation Of Footwear Manufacturing

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