Improvement of A Furniture Production Line Based On Flexsim
Improvement of A Furniture Production Line Based On Flexsim
Improvement of A Furniture Production Line Based On Flexsim
Guo Jidong, Liang Yuyan, Zhang Kaibin, Jiang Junhao, Feng Caiping, Mo Yuwei,
Zhang Yongyang, Zhou Dawei
School of Industrial Automation
Beijing Institute of Technology, Zhuhai
Guangdong Zhuhai, China
35189850@qq.com
Abstract
Aiming at the balance and bottleneck process of a furniture production line, this study simulates the production status
by Flexsim modeling and simulation, improves the bottleneck process by using ECRS principle and program analysis,
establishes 0-1 integer programming model for station reorganization, and obtains the optimized workshop processing
flow by using LINGO software. The results show that the total time of the production line is reduced by 87 seconds,
and the production balance rate is increased by 34.7%, which solves the practical problems in production and provides
a reference scheme for production improvement.
Keywords
Flexsim modeling and simulation, 0-1 integer programming model, Lingo software, Production balance rate
Gong Craft
10 48 1
Line
Gong Make the big
6 Hand gongs 11 168 1 425
milling holes
Polish the
12 209 1
side
This paper mainly studies the process flow from cutting to trial assembly in the production line of solid wood
engineering. According to the production process of type B products, after field investigation, the location layout of
No. 1 workshop of the plant is made[2], as shown in Fig. 2.
1. In the layout of the whole production line, the storage area of wood panels has not been reasonably designed
and planned (only simple drawing out the area), which leads to confusion in the placement of wood panels in the
production process, which increases the searching time of operators and causes unnecessary waste of time.
2. The production line lacks unified and standard on-site management. Basically, the production is allocated by
the operators themselves, and the operation action and material placement are in accordance with personal habits. In
production, many operation actions do not conform to the principle of action economy, which is easy to cause
problems such as increasing work load and low production efficiency [3].
3. There is an unbalanced process allocation problem in the production line, which is easy to lead to unbalanced
operation time distribution, resulting in some operators working at high load and some operators in idle state[4].
According to the standard working time of 8 hours a day, the processing rate of cutting process is 16.7%, while
the idle rate of thickening and cold pressing process is only 2.2%. It can be found that the bottleneck process is
thickening and cold pressing. The simulation data analysis table is output from the above simulation model, as shown
in Table 2.
Open
Opening
1 1 sandwich 7% 83.3%
materials
type panel
Brush
2
Thickened glue
2 Cold 97.8% 2.2%
Pressure Thicken the
3
nail frame
Edge
4 6 Banded 29.2% 70.8%
sealing
9 Milling
Gong Craft
10
Line
∑T i
P= i =1
×100%
C.Tmax × N (1)
∑T i
Among them: i =1 is the total time of all workstations calculated according to the data collected above;
C.Tmax is the maximum operation time of all processes; N is the sum of production line workstations, then,
1728.3
P= ×100% = 53.2% .
6 × 541
The balance rate of the production line calculated above is 53.2%, which is far lower than 86% of the production
target balance rate. The reason for the imbalance of the production line is that the production rate of each process is
unbalanced, and the imbalance of production capacity among the processes will lead to the accumulation of work in
process and other problems, resulting in the waste of waiting.
3. Improvement plan
3.1 Methods and steps
In the first step, based on the relevant theoretical basis of ECRS, the bottleneck station in the current bottleneck process
is improved combined with action analysis, and the balance rate of the production line is compared with the target
balance rate [7]; the second step is to rearrange the stations by using the 0-1 integer programming modeling analysis
method of operational research, and the balance rate of the production line is compared with the target again; the third
step is to achieve the goal According to the process determined by lingo software, Flexsim simulation modeling
evaluation is carried out according to the process determined by lingo software, and the production line layout is
optimized. If it is not up to the standard, cycle steps 1 and 2. [8]
Table 3. Program analysis chart of nail frame thickening process (before improvement)
Table 4. Program analysis chart of nail frame thickening process (after improvement)
Process 1 2 3 4 5 6
2— 4—
1--91 6--165 7--92 10--48
Work
154.5 79.3
station
number -
3—
Work 5--180 8--87 11--168
station 308.5
productio
n time
9--68 12--209
Process
91 463 259.3 165 247 425
time
Total
1650.3
time
Balance
59.41%
rate
In the second step, Lingo software is used to solve the problem and get the solution status and solution report, as
shown in Fig. 4 and 5.
The results are shown in Table 6. When the process number M = 6, the minimum production cycle CT of solid
wood production line is 320s, and the production balance rate is increased to 86%.
Process 1 2 3 4 5 6
Process Process
Total Processing
serial production Idle rate
time/ s rate
number time/ s
After the re layout of workshop No. 1, the products produced in large quantities and the products of many varieties
and small batches flow through the stations involving equipment and manual operation, which are arranged in two
lines, reducing the backflow of work in process during production and making the layout more reasonable [13].
4. Conclusion
The results of this paper show that traditional IE combined with operations research and lingo can solve the furniture
production problem of cluster type very well [14]. The traditional IE method is used to solve the bottleneck process
problem, which reduces the total production line time of workshop 1 by 78S. Operations research combined with lingo
solves the production line balance problem, making the production line balance rate reach more than 86% [15], which
provides a theoretical reference for solving furniture production problems.
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Biographies
Guo Jidong is a lecturer in the School of Industrial Automation of Beijing Institute of Technology, Zhuhai,
Guangdong, China. He earned B.S. in Mechanical Manufacturing Technology and Equipment from Central South
Institute of Technology, Masters in Mechanical Design and Theory from Dalian University of Technology, China.
He mainly studies engineering graphics, computer aided design, process improvement, etc.
Liang Yuyan is 21 years old, borned in guangdong province, majored in Industrial Engineering, Grade 18, Zhuhai
College, Beijing Institute of Technology. In this paper writing, she was mainly responsible for the work of copy
writing. She has won several prizes in school competitions and thinks she has room for continuous improvement.
Hoping this conference will be held smoothly.
Zhang Kaibin. from Zhuhai Institute of Beijing Institute of Technology. In this project he made together with his
friends in his last college years. He was mainly responsible for collecting data, sorting out data, writing papers and
arranging the work of each group. It is a great honor that this project was selected by the organizer. Hoping the
conference will be a complete success.
Jiang Junhao is 24 years old, borned in Zhaoqing.He graduated from Beijing Institute of Technology,Zhuhai. His
major is IE(Industry engineering). Now, he worked in a medium and small-sized enterprises(export oven). He used
industrial engineering knowledge to solve production problems, and participated in many projects,including the
establishment of material distribution and delivery system,the Layout optimization and site improvement.It gave me
a great sense of accomplishment.
Feng Caiping is 23 years old borned in Huizhou City, Guangdong Province. She is studying in Zhuhai College of
Beijing Institute of Technology, majoring in industrial engineering. During her school years, she always try her best
to do everything well, that is, she can get all-round development, mastering the basic knowledge of my major well,
actively participate in community activities, and successfully pass CET-4 and Putonghua proficiency test.
Mo Yuwei is 23 years old, borned in guangdong province ,studying in Beijing University of Technology of Zhuhai.
My major is industry engineering. She spends most of her time on study, passed CET 4 . and had acquired basic
knowledge of her major during her school time.In school, she won the honorary title of excellent student and
excellent League member, also won the third prize of excellent student scholarship in 2018 and the second prize of
excellent student scholarship in 2020.
Zhang Yongyang is employed as an Assistant Professor and Director of Industrial Engineering by Beijing Institute
of Technology, Zhuhai. He earned a Master degree of Industrial Engineering from Chongqing University. He has
been recognized as a professional management with over 10 years of experience in the automotive industry. His
research interests include intelligent manufacturing, flexible production, facility planning, resource optimization and
lean production.
Zhou Dawei is a senior engineer, master of industrial engineering, industrial engineering expert of China
Mechanical Engineering Society, research direction: industrial engineering application, teaching courses: system
engineering, basic industrial engineering, production planning and control, lean production, etc.