Modeling, analysis and optimization of carousel-based flexible manufacturing system

Abstract

This manuscript presents an approach to model, evaluate, and optimize a mixed-model carousel-based flexible manufacturing system (FMS). In the proposed FMS, a carousel-based layout is enclosed by different manufacturing cells and assembly cells, which are equipped with multiple multipurpose machines (undergoing planned breakdowns), robots and a conveyor for the production and assembly tasks. The FMS exhibits intra and inter-cellular routing flexibility allowing the parts to adopt different routes within cells and in between cells to ensure continuous production under planned resources failure conditions. For system modeling, a comprehensive hierarchical Colored Petri net (CPN) approach is used, and the result of several input variables has been revealed on the output indicators in particular cycle time, throughput, and work-in-process (WIP). Further, the design of experiment (DoE) and response surface methods (RSM) have been employed for system optimization. The cycle time and WIP responses have been minimized and throughput has been maximized.

Keywords Breakdowns and repairs, Colored petri net, Flexible manufacturing system, Modeling and simulation, Optimization