Int. j. econ. manag. soc. sci., Vol(4), No (1), January, 2015. pp.

12-17

TI Journals

International Journal of Economy, Management and Social Sciences

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ISSN:
2306-7276

Copyright 2015. All rights reserved for TI Journals.

Determining the Optimal Performance of Flexible Manufacturing

Systems using Network Analysis and Simulation Process
Ainaz Ebrahimi
Graduate student, Industrial Engineering Department, Islamic Azad University, Najafabad Branch, Iran.

Seyed Mojtaba Sajadi *

Assistant Professor, Faculty of Entrepreneurship, University of Tehran, Tehran, Iran.

Parviz Roshanzamir
Graduate student, Islamic Azad University, Bojnourd Branch, Iran.

Mohammad Azizi
Assistant Professor, Faculty of Entrepreneurship, University of Tehran, Tehran, Iran.
*Corresponding author: msajadi@ut.ac.ir

Keywords

Abstract

Flexible Manufacturing System

Simulation
Analytical Network Process
Performance Optimal level

Global competition in the manufacturing industry with aims to increase diversity of products, reduce product
delivery time and customer satisfaction, improve quality and reduce production costs, is increasingly
growing. Faced with these multiple issues, new technologies that support automation and flexibility have
been made. In this regard, the use of flexible systems in products and production processes has been
emphasized. Proper functioning of such systems requires good management factors, therefore, this study
aims is to determine the optimal level of performance. In the first phase of the study, the main factors
affecting the performance of the prioritization and selection is paramount when considering an overview of
the process of network analysis, to determine the best factor is used. Our results indicate that the use of these
methods will help to significantly advance manufacturing systems. Because plant managers focused on the
main plot, they can reach an optimal level of performance and other achievement such as increase revenue
and reduce costs will have for manufacturing industries.

1.

Introduction and literature review

Due to the competitiveness of the manufacturing industry in recent decades has grown and increasingly more focuses on flexibility and rapid
response to changing market conditions. Flexible manufacturing systems (FMS) including systems due to its high flexibility to be able to
respond to these changes. Success in producing in such systems need to manage change and adapt to situation. The problem about Management
issues related to production in flexible manufacturing systems can be considered as the planning or scheduling problems. FMS planning
problems that must be resolved before system operations, is including the selection of components, grouped machinery, determine production
rate (parts), resource allocation (pallets and fixtures) and loading problem. While FMS scheduling problems is involved in implementing parts of
the system and the schedule the part flow in manufacturing systems. This particular subject is listed [1]. In Assessment FMS systems, is given
some of the most important criteria. Achieve the completion date, the maximum system / efficiency machines, Minimum number of components
in the construction of WIP, the maximum of production rate, minimum of preparation time and switching devices, the minimum of the average
time streaming (parts) and balancing machinery. In this paper, we aim to optimize the performance of the hierarchical flexible manufacturing
system that is a combination of a small unit. The system considered in this study is a two level unit that each level includes a workstation and
each cell has a number of machines. Machines at each workstation are connected by intermediate storage and also there are a central part loading
/ unloading time. In order to optimize the performance of FMS, many parameters must be considered that include: the type of pieces, sequencing
the pieces, cost of transfer between workstations, the distance between the machines, intermediate storage size, cycle time, batch sizes.
Therefore, in this paper, in order to obtain the best factor (variable) optimizing the objective function, we consider the parameters of the
optimization objective function and Then, by using multi-criteria decision-making techniques, the best factor gain. Since there are dependencies
between these factors, ANP technique is used. After the above variables, we simulated the objective function as Max or Min of a set of
constraints using simulation software ARENA. In this research the first study is talk about generalities. The literature study will examine which
factors influence performance have been studied. Optimal levels of performance are also described. Then ANP technique, Criterions prioritized
and according to the given superior operating as Target, model simulations are performed. Finally, the results of simulation experiments are
analyzed.

2.

Methodology

Using a flexible manufacturing system (FMS) Facilitates manufacturing business with aim to improve performance, customer-centric products
and production flexibility makes in average volume. A flexible manufacturing system can be defined under the configuration of the control of
semi-independent computer workstations, and material handling systems, which fly more efficient and effective in a wide variety of medium to
low volume parts designed [7]. In fact, a flexible manufacturing system that is designed to produce varied types of parts has low to moderate
volume. Therefore, it is a more efficient production system compared with a much lower diversity of components in large scale production. FMS
are generally designed that human intervention and is changes time range making in the minimum [8].
2.1 FMS performance
The FMS has several components. The main components include [3], [11], and [2]:

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Determining the Optimal Performance of Flexible Manufacturing Systems using Network Analysis and Simulation Process
International Journal of Economy, Management and Social Sciences Vol(4), No (1), January, 2015.

Machine productivity: measurement and evaluation is based on each machine and each piece. Indicators for the evaluation of the case
have been assigned, including setup time, processing time and are maintenance activities.
Transmission time: Spare when signing in system require several time. Transmission time is the time that the parts are on the move
between workstations or in different parts of the system, by humans, robots, and transportation systems.
Production time: as long as the parts are being processed on machines in their manufacturing process can be applied.
WIP: Material that has entered the production process but is not yet a finished product. Work in progress (WIP) therefore refers to all
materials and partly finished products that are at various stages of the production process. WIP excludes inventory of raw materials at
the start of the production cycle and finished products inventory at the end of the production cycle.
Blocking Factors: these factors in flexible manufacturing systems can make the interrupt due to the queue created in a machine or due
to a specific component. Also, the flow of resources and lack of access to resources or the entrance and exit parts can cause disruption
to production. So any event that would make a dent in the production, as the gap (Blocking), is called.
Make span: in fact, is the time between the beginning and the end of production of the products or tasks refers to a sequence which has
a significant impact on performance.
Output: is the most important factor in the performance enhancement with respect to the desired output is specified in terms of time
and quality.

To design an efficient flexible manufacturing system, an information system is incorporated to interface and integrate the entities of FMS, the
mode of synchronizing the various entities and the method of coordinating them in order to achieve the objectives [18]. Buitenhik et al describe
that the components of an FMS are generally expensive therefore the design of these systems is an important issue. Stecke and Solberg report on
an experimental examination of a real FMS. The system consists of 9 machining centers, an inspection station and a control queuing area
connected by an automated material handling system. The number of finished parts was considered as the system performance measure. In recent
studies pertaining to the FMS, researchers have been very keen to improve the performance of flexible manufacturing system [17].
Some researchers have used deterministic models to estimate the FMS performance; these models are very useful for estimating system
parameters such as production rate and resource utilization at a beginning stage of design.
Solberg [13] and Mejabi[12] presented a universally accepted mathematical model (deterministic in nature) to evaluate various performance
measures of an FMS. Montazeri and Van Wassenhove [11] investigated the performance of a number of dispatching rules for FMS.
Chan et al [5] initiate an idea to extend the performance analysis to FMS related technologies such as supply chains. It is found in literature that
performance improvement studies often involve the use of simulation experiments. Ali and Wadhwa [17] performed simulation experiments to
evaluate the effect of various flexibility types and control rules on the performance of FMS.
Simulation modeling has been broadly proposed by the researchers for the analysis of complex systems. It provides a simple platform to model
the variables that are complicated to model mathematically or which involves improbable assumptions. Therefore, simulation is suitable for
representing a complex system to get a feeling for the real system. It may be especially true for FMSs with a heterogeneous and dynamic
environment where on-line control strategies with respect to time are employed [5].
Tunali [16] developed a simulation model of a job shop type FMS. The model was used to investigate how the performance of scheduling
decisions (i.e. mean job flow time) is affected by the use of flexible or prefixed part process plans, in case of a machine breakdown situation. In
general, there are two types of problem that need to be addressed in an FMS, namely design problems and operational problems [6]. The former
deals with selection of FMS components while the latter concerns the utilization aspects of FMSs.
This paper focuses on both aspects of FMS problems, first the operational study of existing FMS and secondly a new FMS has been designed
and simulated to depict the proposed performance improvement plans of the firm. The case considered in this paper requires contribution in
terms of introduction of performance improvement strategies to the firm. A simulation model has also been developed to design and estimate the
performance measures of new FMS. The effort is also made to suggest some improvement strategies to the company as a feedback statement
which results in higher production rate and better utilization of system resources.

3.

Prioritize factors

After determining the factors affecting the performance of the system in the previous section, will be paid to ranking factors. According to the
previous studies, due to the correlation between these factors the network analysis process approach in order to prioritizing has been used.
3.1 make a decision network structure
In this section, with consideration of the criteria, sub criteria, options and the problem, make a network decision. Network elements are listed in
Table 1. Decision network is shown in Figure 1. After the make a decision network, between options and criteria, is making by using expert
survey. The Super matrix in Table 2 is shown as a result of paired comparisons. Finally, using normal super column matrix, the better option is
specified. The best option is to increase the output and efficiency of machinery. The resulting chart is presented in Table 2.
3.2 Define the problem based Simulation
One small production system has been designed in two levels. The system consists of three pieces of products in categories with specific
sequences, is generated. Characteristics of this system are summarized below. Simulations are performed for 40,000 hours. The target of this
simulation is maximum system output with respect to a series of restrictions that these limitations are:
1 - Failure and time of repair
2 - The maximum amount of reliability
3 - The number of tools available
4 - Fixtures available
5 - Palettes available
Transportation systems are pallet and conveyor that features considered below. The system components include log part, two productive cells in
each levels (two-level system specification is assumed to be the same at any level), and exiting parts. Each level consisting of two cells, each cell
has two machines. Machines are different in every cell function. The system provides three different pieces. Arrival time between two
consecutive parts (all types), have exponential distribution with mean 20 minutes. The first piece entered at time zero. Piece of 1: 40%, 2:30%,
and the 3: 30% Make up the total production. Part Sequences and process times (in minutes) is shown in Table 3. Entire process has a triangular
distribution.

Ainaz Ebrahimi, Seyed Mojtaba Sajadi *, Parviz Roshanzamir, Mohammad Azizi

14

International Journal of Economy, Management and Social Sciences Vol(4), No (1), January, 2015.

This system has a central loading and loading segment that before entering part to machines, these parts are mounted on the fixture,
and then placed on a pallet and move towards a machine for processing.
Close fixtures have exponential distribution with mean 5 minutes and put on pallets and the removal of fixture is a triangular
distribution with values (1.5, 1, 0.5). Conveyor speed is assumed 1 part per unit time.
Number of components in the system are allowed to be in operation only depends on the number of available pallets which is not
assigned. Number of pallets will vary between 9 and 14.
Operational policy, FIFO, is intended to send parts to the workstation.
It is assumed that three types of fixtures are available for every type of part.
The total number of available tools for processing all parts of the system type is 10.

3.3 The simulation model

In this section, with consideration the characteristics of the data and assumptions, and the goal is to increase the output and efficiency of
machines, the study is simulation by Arena software. The problem is simulated in the optimal and Pre-optimal model. The difference between
these two models is in the details. In this model, finding bottlenecks that lead to reduced productivity and output, and eliminate the bottlenecks
optimal model is obtained.
3.4 Analysis of existing and optimal models
The simulation model is presented, followed by sore point for achieving optimum performance. In this case, as has been said previously, factors
affecting performance include the number and sequence of parts, costs, resources, costs transfer stations, distances between stations, periods of
busy / idle and layouts condition. Among these factors, in this study, the resource cost and the distance between stations factor, according to the
cost of which was estimated, has the most significant impact on the costs and revenues and also have direct influence on the output and
productivity in the system. By changing this factor, the results of income, expenses, profits, productivity, resources, outputs, in the optimal
model has significant improvement over existing models. For example income and profit in Pre-optimal model and optimal model are shown in
figure 3 and 4.
3.5 Estimated cost - income due to the change
Changes that have been made in the model are as follows:
1 - Change the distance between workstations (change in length of the conveyor)
2 - Change in the number of sources
Revenue and total cost of the optimal model is calculated by the following expression:
Total cost = instrument Cost + cost of machinery + cost of fixtures and + cost of pallets = 2832290000
Total revenue during each simulation= Revenue per part= Part A 000/80 + Part B 000/80+ Part C 000/80 =8234300000
Profit = Revenue - Cost = 5302010000
Output products = 119652

(1)
(2)
(3)
(4)

Should be noted a decrease in the number of sources and Conveyor length through the trial and error, With a view to establishing a balance
between costs and output revenues and benefits, productivity gains of the system has been made. In the optimal model, nearly two-thirds of the
previous conveyor length is reduced. The source of the almost 1/2 are reduced. The cause of declining resources is the time of high idle time and
therefore high costs associated with it. And also reduce the length of the conveyor is due to the reduce the cost and time of moving parts. Is
noteworthy that, down to the transporters or the distance between stations is very expensive; Therefore, these costs must be added to the overall
cost of the system.
Revenue and total cost of Pre-optimality models is calculated by the following expression:
Total cost of the system during simulation =2623869000
Total revenue during the simulation =8990140000
Profit =5566271000
Output = 120325

(5)
(6)
(7)
(8)

With respect to the cost of reducing the distance between stations, that is estimated at about one hundred million, so revenues and profits will be
as follows:
Total cost = 2723869000
Income = 8190140000
Profit = 5466271000

(9)
(10)
(11)

Now, by using the relation of benefits to costs, the optimal model is discussed.
Pre-optimal model:

= =

Optimal model:

= =

= 0.52

=2.87
=3

(12)
(13)
(14)

Therefore, with consideration the above results and the greater number of benefits and costs of the optimal model according to Table 2, the
model is chosen to be less expensive. And with regard to the increasing output and efficiency of machinery in order to reduce costs, delivery
time and increase revenue and profits. The optimal model can improve the performance of considered flexible manufacturing system.

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Determining the Optimal Performance of Flexible Manufacturing Systems using Network Analysis and Simulation Process
International Journal of Economy, Management and Social Sciences Vol(4), No (1), January, 2015.

4.

Tables and results of simulation of arena software

Table 1. Criteria, sub-criteria and decision options for making the decision network
Objective: To determine the optimum level of production flexibility
options
Sub-criteria

Increase the output and efficiency of

machines (EF)
Decrease the WIP and blocking factors
(CD)
Reduce production time and transmission
time (AB)

criteria

Number of part in a batch (P1)

Type of part in a batch(P2 )
Sequencing of part (P3)

part

Cost of resources (C1)

Cost of transmission between station (C2)

cost

Busy time (T1)

Idle time (T2)

time

Destination between station (L1)

Machine Layout (L2 )

Layout

Figure 1. A decision network in selecting the best factor

Table2. Distribution Super Matrix

T

0
T
L
C

0.21
0.18
0.05

T1

T2

L1

L2

0
0.21
0.18
0.05

0.21
0.18
0.05

C1

C2

P1

P2

P3

0
0.21
0.18
0.05

0.21
0.18
0.05

0.21
0.18
0.05

0.21
0.18
0.05

0.21
0.18
0.05

0.21
0.18
0.05

0.21
0.18
0.05

AB

CD
0

0.21
0.18
0.05

0.21
0.18
0.05

0.21
0.18
0.05

0.21
0.18
0.05

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

T1
T2

0.033
0.028

0.033
0.028

0.033
0.028

0.033
0.028

0.033
0.028

0.033
0.028

0.033
0.028

0.033
0.028

0.033
0.028

0.033
0.028

0.033
0.028

0.033
0.028

0.033
0.028

0.033
0.028

L1
L2
C1
C2
P1
P2
P3

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

0.044
0.017
0.077
0.027
0.042
0.025
0.011

AB
CD
EF

0.291
0.126
0.08

0.291
0.126
0.08

0.291
0.126
0.08

0.291
0.126
0.08

0.291
0.126
0.08

0.291
0.126
0.08

0.291
0.126
0.08

0.291
0.126
0.08

0.291
0.126
0.08

0.291
0.126
0.08

0.291
0.126
0.08

0.291
0.126
0.08

0.291
0.126
0.08

0.291
0.126
0.08

EF

Ainaz Ebrahimi, Seyed Mojtaba Sajadi *, Parviz Roshanzamir, Mohammad Azizi

16

International Journal of Economy, Management and Social Sciences Vol(4), No (1), January, 2015.

0.8
0.6
0.4
0.2
0
AB

CD

EF

Figure 2. The options considered normal weight

4
4
4

Machine1
3,5,8
3,5,8
-

3
3
3

Machine2
5,9,12
5,9,12

Machine1
4,6,8
4,6,8

2
2
2

Sequence
Time
Machine2
Machine1
4,6,8
3,6,9
4,6,8
3,6,9
4,6,8
3,6,9

Figure 3. Results in a model of optimal income and expenses

Figure 4. Results of revenue and expenses in the Pre-optimal model

1
1
1

Part type

Machine2
4,7,10
4,7,10
-

cell

Machine1
4,6,8
4,6,8
4,6,8

Sequence
cell

Machine2
2,4,6
2,4,6
2,4,6

Sequence
cell

Sequence

cell

Table 3. The process time

Part1
Part2
Part3

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Determining the Optimal Performance of Flexible Manufacturing Systems using Network Analysis and Simulation Process
International Journal of Economy, Management and Social Sciences Vol(4), No (1), January, 2015.

5.

Conclusion

In regard to that, today's most important environmental values are the ability to create a competitive advantage in today's dynamic environment
industry. In this regard, the use of improved systems and a flexible in products and production processes was emphasized. In the past, technology
and expertise in design and manufacturing were two major factors that considered in determining the competitiveness of companies. But today
the successful performance and cost effectiveness measures, depends on the factors such as reducing the costs of facilities, equipment and
increasing equipment efficiency.
The study was to analyze the existing system and prepare a plan to improve the performance of system. Simulation modeling has been utilized to
achieve the objectives. Initially various operational and performance parameters were calculated then the new FMS has been proposed with the
optimum number of servers. It is discovered that the Maximum output and will improve performance. The system utilization was another
important issue which has been addressed in this study, it is also found that in existing system the resources were not properly utilized as some
stations like loading/unloading. Thus, taking into account the existing system and the simulation results, changes in sources and distances,
simulation optimization model was presented.
The findings of this study have important managerial significance. The management can obtain better insight and guidelines for determining
various decisions relating to process and operations improvement and investment in new facility. These results and findings have also been
forwarded to the company management for further implementation analysis purpose. Other operating conditions of system like system layout,
material handling systems etc. can also be considered in future and the effect of these parameters can also be studied using our simulation model.
In future it is also intended to conduct various simulation experiments so that system would be robust enough to handle all situation and dynamic
market conditions.

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[14]
[15]
[16]
[17]
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