Högskolan i Skövde

Manufacturing sectors in Sweden have a long history that leads to common non-optimized flows on the shop floor. Especially when having a really high product mix and a low-volume of customized products, a great deal of effort with respect to flow optimization is needed to stay present and compete in the globalized market. The goal of this project is to support the design and development of the implementation of new production systems and logistics flows considering the shop floor plant layout of a Swedish middle-size water pumps factory. In this paper, with the help of different types of simulation models and optimization, some results of a new technologically adapted production line are analyzed and relevant information and potential improvements in the production are found. The further development of optimization studies using the exiting simulation models is stated as ongoing and future work. The obtained and potential results can serve for decision makers and stakeholders to apply changes and adaptations in the system considering the mid and long term goals of the company.

Nowadays, due to the need of innovation and adaptation for the mass production of customized goods,many industries are struggling to compete with the manufacturing sector emerging in different countriesaround the world. The understanding and implementation of different improvement techniques isnecessary in order to take part in the so-called fourth industrial revolution, Industry 4.0. This paperinvestigates how two well-known improvement approaches, namely lean and simulation-basedoptimization, can be combined with the concepts of Industry 4.0 to improve efficiency and avoid movingproduction to other countries. Going through an industrial case study, the paper discusses how such acombination could be carried out and how the different strengths of the three approaches can be utilizedtogether. The case study focuses on how the efficiency of a production site can be increased and howIndustry 4.0 can support the improvement of the internal logistics on the shop floor.

Companies are continuously working towards system and process improvement to remain competitive in aglobal market. There are different methods that support companies in the achievement of that goal. This paper presents an innovative process that combines lean, simulation and optimization to improve the material flow of a manufacturing company. A description of each step of the process details the lean tools and principles taken into account, as well as the results achieved by the application of simulation and optimization.The project resulted in an improved layout and material flow that employs an automated guided vehicle. In addition, lean wastes related to transport, inventory levels as well as waiting times were reduced. The utilization of the process that combines lean, simulation and optimization was considered valuable for the success of the project.

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.

Facility layout design (FLD) is becoming more challenging than ever. In particular, modern day manufacturing industry requires advancing from a traditional approach of mass production to one of mass customization including increased flexibility and adaptability. There are several software tools that can support facility layout design among which simulation and optimization are the most powerful – especially when the two techniques are combined into simulation-based optimization (SBO). The aim of this study is to identify the challenges of SBO in FLD of production systems. In doing so, this paper uncovers the challenges of SBO and FLD, which are so far addressed in separate streams of literature. The results of this study present two novel contributions based on two case studies in the Swedish manufacturing industry. First, that challenges of SBO in FLD, previously identified in literature, do not hold equal importance in industrial environments. Our results suggest that challenges in complexity, data noise, and standardization take precedence over challenges of SBO in FLD previously reported in literature. Second, that the origin of challenges of SBO in FLD are not technological in nature, but stem from the increased complexity of factories required in modern day manufacturing companies.

Facility layout design is becoming more challenging as manufacturing moves from traditionally emphasised mass production to mass customisation. The increasing demand for customised products and services is driving the need to increase flexibility and adaptability of both production processes and their material handling systems. A holistic approach for designing facility layouts with optimised flows considering production and logistics systems constraints seems to be missing in the literature. Several tools, including traditional methods, analytic hierarchy process, multiple-attribute decision making, simulation, and optimisation methods, can support such a process. Among these, simulation-based optimisation is the most promising. This paper aims to develop a facility layout design methodology supported by simulation-based optimisation while considering both production and logistics constraints. A literature review of facility layout design with simulation and optimisation and the theoretical and empirical challenges are presented. The integration of simulation-based optimisation in the proposed methodology serves to overcome the identified challenges, providing managers and stakeholders with a decision support system that handles the complex task of facility layout design.

Optimizing production systems is urgent and indispensable if companies are to cope with global competition and a move from mass production to mass customization. The urgency of this need is more obvious in old production plants with a history of modifications, expansions, and adaptations in their production facilities. It is common to find complex, intricate and inefficient systems of material and product flows as a result of poor production facility layout. Several approaches can be used to support the design of optimal facility layouts. However, there is a lack of a suitable generic methodology for designing such layouts. Additionally, there has been little focus on the data and resources required, or on how simulation and optimization can support the design of optimal facilities. To overcome these deficiencies, this paper studies the integration of simulation and optimization for the design and improvement of facility layouts taking into account production and logistics constraints. The paper includes a generic perspective and a detailed implementation. The proposed methodology is evaluated in two case studies and by drawing on the principles and tools of the functional resonance analysis method. This method analyzes the implementation order and variability of a group of processes that can lead to unwanted outcomes. The results can provide managers and other stakeholders with a methodology that adequately considers production and logistics constraints when seeking an optimized facility layout design.