Input Data Analysis for Detailed Flow Simulation of Manual Assembly Lines

Abstract: This thesis work was carried out at a manufacturing plant in Sweden and they are producing a different kind of components for the company. This thesis work was about an assembly line in the factory where they needed a simulation model in Plant Simulation. The main goal of the thesis work was to break down different losses, building a simulation model and compare it if the results are the same as the real assembly line with similar characteristics. The assembly line consists of several workers and AGVs with three u-shaped lines. Frame of reference describes topics that are related to the project. It consists of theories about simulation, collection of data, the bottleneck of the production line, integrated manufacturing systems and flexible workers. The chapter of literature review presents researches on similar studies, in this case, simulation, bottleneck, and workers in the assembly line. In the chapter Simulation model, there will be an explanation of how data got collected, the transformation of raw data and building a simulation model of it. Also the way the model was programmed and built. Result and analysis, the focus is to analyze the throughput, lead time and work in process parameters to get a steady state graph and confidence interval. This chapter also shows how long time does the model need for warm up and how many replications it needs to be more accurate. Discussion part reviews the whole project and its progress. It covers problems that authors got through, at the same time learning and getting a new experience of tools and methods that were used in this project.