A Tailored Fuzzy Simulation Integrated with a Fuzzy DEA Method for a Resilient Facility Layout Problem: A Case Study of a Refrigerator Injection Process

Abstract When a process diagnosed as a bottleneck in a manufacturing system, we can improve its performance by redesigning the layout of facilities. In this study, the facilities are considered resilient for the first time, since due to resilience engineering principles the flexible and redundant facilities are considered in the production line beside the maintenance center with teamwork between its members. To encounter the proposed single-row facility layout problem, a unique fuzzy simulation and fuzzy mathematical model is tailored. In this regard, a discrete-event-simulation method is used to model all the possible layouts of an injection process. Then the results of the fuzzy simulation are imported to the fuzzy data envelopment analysis (F-DEA) to rank different layouts and find the optimal one. The criteria for this assessment are average waiting time (WT) and utility of resource (UR) as conventional key performance indicators (KPIs), in addition to fault tolerant, and flexibility as resilience engineering factors. Finally, the weights of the effective factors are obtained by sensitivity analysis. Also, implementing an integrated model in a real case study of a refrigerator injection process for a home appliance firm in Iran presents the solution quality.

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