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Please use this identifier to cite or link to this item: http://hdl.handle.net/123456789/3376

Title: ASSEMBLY LINE MODELING AND SIMULATION OF FOOTWEAR MANUFACTURING (A Case Study on Ramsey Shoe Factory)
Authors: Mulugeta, Nahom
Advisors: Dr. - Ing Daniel Kitaw
Ato Temesgen Garoma (Phd candidate)
Keywords: assembly lines
simulation software
WIP
Copyright: Sep-2011
Date Added: 17-Jul-2012
Abstract: In today’s competitive global market, companies are mostly striving to strengthen themselves as much as possible in all competiveness dimensions of business. This demands for optimal production system which increases the overall productivity of the company. Survival of any business in today’s competitive market place depends mainly on response time, production cost, market price and flexibility of manufacturing. These things motivated continuous research in modeling and performance evaluation of manufacturing systems. In parallel to this, different simulation software play a great role in designing a model of a real system and conducting experiments with this model for the purpose of understanding the behavior of the system and evaluating various strategies and scenarios for the operating or manufacturing system. Since the majority of consumable and non consumable goods are manufactured on assembly line system; assembly line balancing problem is getting importance now a day. Footwear is one of the goods which are manufactured on assembly line system. Hence, this thesis is concerned with the modeling and simulation of assembly line balancing of footwear manufacturing in Ramsey Shoe Factory. Within the production department this thesis is mainly concerned with the modeling and simulation of the two assembly lines: Stitching and Lasting assembly line. To do so, Arena simulation software is employed to model and measure performance of existing manufacturing systems of both assembly lines. Based on the simulation model result of the existing system, different scenarios are proposed to solve observed problems of the existing manufacturing system. Problems that are identified in simulation model analysis were: Line balance efficiency for both assembly lines is low, Relatively high level of WIP is observed in some work station of stitching assembly line, low production output with respect to the installed capacity, and the output of stitching assembly line is significantly higher than that of the lasting assembly line which causes WIP of different model shoes to be piled up in between the two assembly lines. To solve these problems, five possible scenarios are developed. These are: Avoiding unnecessary duplication resource from station with low capacity utilization, merging similar operations with low resource utilization together and assign to one worker, increasing level of resource at stations with high WIP, changing working method, and combination of all the above alternatives. Among the five developed scenarios, the last one, ‘Combination of all the above alternatives’ gives better performance of footwear manufacturing for the selected model shoe.
URI: http://hdl.handle.net/123456789/3376
Appears in:Thesis - Mechanical Engineering

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