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Simulation-based Optimization for Facility Layout Design in Conditions of High Uncertainty
Mälardalen University, Eskilstuna, Sweden.
University of Skövde, School of Engineering Science. University of Skövde, The Virtual Systems Research Centre. (Produktion och automatiseringsteknik, Production and Automation Engineering)ORCID iD: 0000-0003-4180-6003
Mälardalen University, Eskilstuna, Sweden.
Division of Industrial Engineering and Management, University of Uppsala, Uppsala, Sweden.
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2018 (English)In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 72, p. 334-339Article in journal (Refereed) Published
Abstract [en]

Despite the increased use of Simulation based Optimization, the design of facility layout is challenged by high levels of uncertainty associatedwith new production processes. Addressing this issue, this paper aims to understand the conceptual modeling activities of Simulation-basedOptimization for facility layout design in conditions of high uncertainty. Based on three in-depth case studies, the results of this paper showhow characterization criteria of production systems can be used in conceptual modelling to reduce uncertainty. These results may be essentialto support managers and stakeholders during the introduction of new production processes in the design of facility layouts.

Place, publisher, year, edition, pages
Elsevier, 2018. Vol. 72, p. 334-339
Keywords [en]
uncertainty reduction, simulation based optimization, facility layout, decision support, production system design
National Category
Other Engineering and Technologies not elsewhere specified
Research subject
Production and Automation Engineering
Identifiers
URN: urn:nbn:se:his:diva-15189DOI: 10.1016/j.procir.2018.03.227ISI: 000526120800057Scopus ID: 2-s2.0-85049552085OAI: oai:DiVA.org:his-15189DiVA, id: diva2:1211030
Conference
51st CIRP Conference on Manufacturing Systems, Stockholm, May 16-18, 2018
Funder
Knowledge Foundation
Note

CC BY-NC-ND 4.0

Edited by Lihui Wang

Special thanks to the Swedish Knowledge Foundation for research funding, the industrial partners for giving us the opportunity to develop this project, the IPSI research school at the University of Skövde and Innofacture research school at Mälardalen University for their continuous support.

Available from: 2018-05-30 Created: 2018-05-30 Last updated: 2022-07-15Bibliographically approved
In thesis
1. Facility layout design with simulation-based optimization: A holistic methodology including process, flow, and logistics requirements in manufacturing
Open this publication in new window or tab >>Facility layout design with simulation-based optimization: A holistic methodology including process, flow, and logistics requirements in manufacturing
2020 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Adaptability and flexibility are becoming key concepts in manufacturing. Today manufacturing companies often have to deal with random disruptive events, which necessitates significantly more complex manufacturing systems. Mass customization (manufacturing customized products with mass production efficiency) has also considerably increased the complexity of facility layouts, that is, the physical arrangement of the different aspects required to create products in a factory. Design and improvement of facility layouts is considered a major industrial problem as it affects so many aspects of business. Even in industrialized countries with a long manufacturing history, it is common to find facility layouts that lack optimized flows of materials and products. The main reason for this state of affairs is usually a lack of long-term planning, commonly due to continuous changes and adaptations of the production systems in the layout. These problems are exacerbated by today’s shortened product life cycle.Simulation and optimization are well suited to improve complex manufacturing systems in which several events occur at the same time with unpredictable situations. Thus this thesis aims to investigate how simulation and optimization, and their combination – called simulation-based optimization – can support the redesign and improvement process for existing facility layouts. A literature review shows there is a gap in the field relating to a holistic approach to optimizing facility layouts taking into account production processes and internal logistics. “Holistic” as used here refers to the consideration of the processes and flows occurring in the facility layout, namely machining, assembly, and internal logistics. The aim of this thesis thus includes proposing a holistic methodology based on discrete-event simulation to optimize processes, flows, and internal logistics related to the facility layout.A methodology is defined as a logical set of methods, and in this thesis the methodology has been developed using a case study method with a design and creation strategy. This approach has been successful in identifying and overcoming both theoretical and empirical challenges in simulation-based optimization of facility layout design. The methodology was evaluated using functional resonance analysis method and industrial case studies, and it has proven to be effective for optimizing facility layouts. These results can thus serve as a guideline for engineers and staff involved in this type of layout project, and as a guideline for managers and stakeholders to support strategic decisions.

Abstract [sv]

Anpassningsförmåga och flexibilitet är nyckelbegrepp för konkurrenskraft i den tillverkningsindustrin. Tillverkande företag står inför en ständigt förändrad omvärld som kräver betydligt mer komplexa produktionssystem än tidigare. Massiv kundanpassning av produkter (dvs. tillverkning av skräddarsydda produkter med massproduktionseffektivitet) är en av de faktorer som bidrar till en ökad komplexitet, inte minst i fabrikslayouterna. Framtagning och förbättring av fabrikslayouter anses vara en stor utmaning inom tillverkningsindustrin eftersom det påverkar så många olika aspekter av verksamheten. Även i länder med en lång tradition av industriell tillverkning är det vanligt att fabrikslayouter inte är optimerade med avseende på flödet av material och produkter. Den främsta orsaken till detta är ofta brist på långsiktig planering, vanligtvis på grund av kontinuerliga förändringar och anpassningar av produktionssystemen. Med alltjämt kortare produktlivscykler ökar problemen än mer.Simulering och optimering är väl lämpade för att hantera komplexa tillverkningssystem där flera händelser oförutsägbart inträffar samtidigt. Denna avhandling syftar till att undersöka hur simulering och optimering, och deras kombination – så kallad simuleringsbaserad optimering - kan stödja omdesign och förbättringar av befintliga fabrikslayouter. En genomgång av litteraturen visar att det finns få studier särskilt vad gäller en helhetssyn på optimering av fabrikslayouter, i denna avhandling benämnt med begreppet ”holistisk”. Med en holistisk ansats avses en samtidig inkludering av de processer och flöden som uppstår i fabrikslayout, produktion och intern logistik. Syftet med denna avhandling är att föreslå en holistisk metodologi baserad på diskret händelsestyrd simulering för att optimera fabriklayouter med hänsyn till processer, flöden och intern logistik.I avhandlingen har metodologin utvecklats baserats på fallstudier med en så kallad ”design and creation strategy”. Detta tillvägagångssätt har framgångsrikt lyckats identifiera och överbrygga både teoretiska och empiriska utmaningar i simuleringsbaserad optimering av fabrikslayouter. Metodiken har utvärderats med hjälp av funktionell resonansanalys och industriella fallstudier, och den har visat sig vara effektiv för att optimera fabrikslayouter. Resultaten från avhandlingen kan fungera som en riktlinje för ingenjörer och personal som är involverade i layoutprojekt, och som ett stöd för chefer och andra intressenter som tar strategiska beslut.

Place, publisher, year, edition, pages
Skövde: University of Skövde, Sweden, 2020. p. 97
Series
Dissertation Series ; 35
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Production and Automation Engineering
Identifiers
urn:nbn:se:his:diva-19303 (URN)978-91-984918-9-0 (ISBN)
Public defence
2021-01-15, ASSAR Innovation Arena, Kavelbrovägen 2B, Skövde, 13:00 (English)
Opponent
Supervisors
Note

ADDITIONAL PUBLICATIONS:

8. System Design and Improvement of an Emergency Department using Simulation-Based Multi-Objective Optimization. Goienetxea Uriarte, Ainhoa; Ruiz Zúñiga, Enrique; Urenda Moris, Matías; Ng, Amos H. C. Journal of Physics, Conference Series, 2015, Vol. 616, no 1, article id 012015

9. A Simulation-Based Multi-Objective Optimization Approach for Production and Logistics Considering the Production Layout. Ruiz Zúñiga, Enrique; Urenda Moris, Matias; Syberfeldt, Anna. Proceedings of the 7th Swedish Production Symposium, 2016

10. The Internet of Things, Factory of Things and Industry 4.0 in Manufacturing: Current and Future Implementations. Ruiz Zúñiga, Enrique; Syberfeldt, Anna; Urenda Moris, Matías. Advances in Manufacturing Technology XXXI: Proceedings of the 15th International Conference on Manufacturing Research, 2017, p. 221-226

11. How can Decision Makers be Supported in the Improvement of an Emergency Department? A Simulation, Optimization and Data Mining Approach. Goienetxea Uriarte, Ainhoa; Ruiz Zúñiga, Enrique; Urenda Moris, Matías; Ng, Amos H. C. Operations Research for Health Care, 2017, 15, p. 102-122

12. A Genetic Algorithm for Bi-Objective Assembly Line Balancing Problem. Nourmohammadi, Amir; Fathi, Masood; Ruiz Zúñiga, Enrique; Ng, Amos H. C. Advances in Manufacturing Technology XXXIII: Proceedings of the 17th International Conference on Manufacturing Research, incorporating the 34th National Conference on Manufacturing Research, 2019, Vol. 9, p. 519-524

Available from: 2020-12-11 Created: 2020-12-07 Last updated: 2023-11-02Bibliographically approved

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