Exploring the scheduling problems in a flow shop environment via simulation

Abstract

This paper discusses the performance of push, pull and hybrid (i.e. long pull) manufacturing scheduling systems in the environmental of a flow shop. The performance analysis is conducted via simulation models of two hypothetical flow shops that encompass either only serial operation, or both serial and assembly operations. The model is simulated under Simfactory II.5, which provides the tool necessary to perform a series of experiments related to common production problems. A comparative analysis is then performed based on the multi-criteria decision method known as the analytical hierarchy process (AHP), in order to evaluate the effects of these variables on the performance of each individual manufacturing system, in terms of machine utilisation, product makespan time, work-in-progress (WIP) inventory control, queuing behaviour and carrying cost. Aspects such as machine breakdown, fluctuating demand, bottlenecks, set-up times, lot size, and unbalanced flow are also considered.