Evaluation and optimisation of manufacturing system using simulation modelling and design of experiment

The application of computer simulation has been proposed and implemented to optimize an integrated manufacturing system using lean manufacturing principles. A simulation model only acts as a tool in examining performance. It is essentially a trial and error methodology, and does not directly provide explanations for observed system behaviors. Therefore, in this paper the use of design of experiment in simulation is studied to solve decision-making problems in integrated manufacturing systems. In order to achieve the objectives described above, the authors have developed a simulation model for a manufacturing process in packaging area. In particular, the authors have been modeling the automatic material handling and storage system served by automatic guided vehicles (AGV) versus packaging lines in a pharmaceutical plant. The lean manufacturing principles have been used to simulate different settings of the process as bottleneck removal, buffer removal and kitting operation introduction. The design of experiment 2^5 factorial design has been used to optimize the scenario.