Redesigning an automated production cell for increased efficiency : Discrete-Event Simulation as a tool to evaluate system designs

Abstract: Date:    4th June 2023 Level:    Master Thesis in Product- and Process Development, 30 ECTS Authors:   William Reimer   Noah Paillon Title:    Redesigning automated production cell for increased efficiency - Discrete-Event Simulation as a tool to evaluate system designs Keywords:   Discrete Event Simulation (DES), Redesign, Production process, Automated Manufacturing System (AMS), Automated production cell, Robotics in production, Simulation, Key Performance indicators (KPIs), Decision-making, Redesigning production systems, Bottlenecks, Deadlocks, Production system development (PSD). Aim:    The aim of this study is to evaluate and redesign an automated production cell at a Swedish manufacturing plant using DES with KPIs, with the goal of increasing the efficiency. Research question:  “When redesigning, what factors influence production efficiency within an automated production cell?”, “What are the challenges when redesigning and increasing efficiency within an automated production cell?” and “How can such challenges be surpassed through the usage of DES with KPIs?” Methodology:   This study is a quantitative research with an inductive approach, including simulation as an experimental tool. In order to identify reliable knowledge, the literature review compared books and scientific publications. The empirical results were obtained by observation and data collection at the production site of the case company, which also involved frequent meetings with company supervisors and production engineers. In order to assess the situation and make conclusions, the empirical results were evaluated and experimented using DES.  Conclusion:   The need of identifying a problem's underlying causes in order to improve efficiency was one of the conclusions made. This was additionally mentioned as one of PSD's primary challenges in redesigning an automated production cell. This implies that in order to increase production efficiency, bottlenecks and deadlocks must be appropriately addressed and adjusted to meet the demands of a production. In order to improve the production efficiency of an automated production cell, DES with KPIs is considered to be a useful approach.