A Comparative Study of Unbalanced Production Lines Using Simulation Modeling: A Case Study for Solar Silicon Manufacturing
In the solar silicon manufacturing industry, the production time for crystal growth is ten times longer than at other workstations. The pre-processing time at the ingot-cutting station causes work-in-process (WIP) accumulation and an excessively long cycle time. This study aimed to find the most eff...
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| Veröffentlicht in: | Sustainability 2022-01, Vol.14 (2), p.697 |
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| creator | Cheng, Chen-Yang Li, Shu-Fen Lee, Chia-Leng Jientrakul, Ranon Yuangyai, Chumpol |
| description | In the solar silicon manufacturing industry, the production time for crystal growth is ten times longer than at other workstations. The pre-processing time at the ingot-cutting station causes work-in-process (WIP) accumulation and an excessively long cycle time. This study aimed to find the most effective production system for reducing WIP accumulation and shortening the cycle time. The proposed approach considered pull production systems, and the response surface methodology was adopted for performance optimization. A simulation-based optimization technique was used for determining the optimal pull production system. The comparison between the results of various simulated pull production systems and those of the existing solar silicon manufacturing system showed that a hybrid production system in which a kanban station was installed before the bottleneck station with a CONWIP system incorporated for the rest of the production line could reduce the WIP volume by 26% and shorten the cycle time by 16% under the same throughput conditions. |
| doi_str_mv | 10.3390/su14020697 |
| format | Article |
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The pre-processing time at the ingot-cutting station causes work-in-process (WIP) accumulation and an excessively long cycle time. This study aimed to find the most effective production system for reducing WIP accumulation and shortening the cycle time. The proposed approach considered pull production systems, and the response surface methodology was adopted for performance optimization. A simulation-based optimization technique was used for determining the optimal pull production system. The comparison between the results of various simulated pull production systems and those of the existing solar silicon manufacturing system showed that a hybrid production system in which a kanban station was installed before the bottleneck station with a CONWIP system incorporated for the rest of the production line could reduce the WIP volume by 26% and shorten the cycle time by 16% under the same throughput conditions.</description><identifier>ISSN: 2071-1050</identifier><identifier>EISSN: 2071-1050</identifier><identifier>DOI: 10.3390/su14020697</identifier><language>eng</language><publisher>Basel: MDPI AG</publisher><subject>Accumulation ; Assembly lines ; Case studies ; Comparative studies ; Crystal growth ; Cycle time ; Genetic algorithms ; Inventory ; Manufacturers ; Manufacturing ; Manufacturing industry ; Optimization ; Production capacity ; Production controls ; Production lines ; Raw materials ; Response surface methodology ; Silicon ; Silicon wafers ; Simulation ; Sustainability ; Work in process ; Work stations ; Workflow</subject><ispartof>Sustainability, 2022-01, Vol.14 (2), p.697</ispartof><rights>2022 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/). 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The pre-processing time at the ingot-cutting station causes work-in-process (WIP) accumulation and an excessively long cycle time. This study aimed to find the most effective production system for reducing WIP accumulation and shortening the cycle time. The proposed approach considered pull production systems, and the response surface methodology was adopted for performance optimization. A simulation-based optimization technique was used for determining the optimal pull production system. 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| subjects | Accumulation Assembly lines Case studies Comparative studies Crystal growth Cycle time Genetic algorithms Inventory Manufacturers Manufacturing Manufacturing industry Optimization Production capacity Production controls Production lines Raw materials Response surface methodology Silicon Silicon wafers Simulation Sustainability Work in process Work stations Workflow |
| title | A Comparative Study of Unbalanced Production Lines Using Simulation Modeling: A Case Study for Solar Silicon Manufacturing |
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