Experimental Design of a Flexible Manufacturing System

Flexible Manufacturing Systems (FMS) deal with varied part and product designs, and allows variation in parts’ processing sequences and production volume change. Its successful implementation results in improvement of capital utilization, higher profit margins, and increased competitiveness. Today, FMS design is complex, where various layout types and material handling system (MHS) devices exist while part inter-arrival and processing times are stochastic. This paper presents a case study to investigate effects of different input factors, including layout and MHS configuration (number, speed and type) on FMS performance measured by total production cost, total flow time and throughput, using simulation. The investigation includes interactions between input factors and identifies the settings that yield optimal performance. Overall, the paper presents a framework that integrates experimental design, simulation, and multi-criteria decision-making to the design of complex manufacturing systems.

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