Simulating an agile, synchronized manufacturing system

Retail customers are demanding more variety, more features and quicker order response times from manufacturers. Furniture production systems have had to become more flexible to respond to the variety of styles, fabrics and patterns offered by retailers. In this make-to-order environment, the orders received must be grouped into specific, logical batches whose short-cycle operations require close coordination and monitoring throughout the facility. For upholstered furniture, each batch may be unique because it consolidates orders having fabrics of different colors, texture or style. In recliner chair and similar production systems, the parallel component subassembly lines must maintain synchronization within each line and between the lines for components to simultaneously reach final assembly. The simulation developed represents an existing production system. It generates expected outputs under conditions of operation variability, queue lengths (buffers) and batch changeover (set-up) times over a range of 3 uniform and feasible batch sizes. Thus, the real-time status and location of components and subassemblies consigned to a specific production batch is essential for maintaining and improving quality and utilization of personnel, space, material and other resources.