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Abstract
In this study, shoe manufacturing is analyzed and specific production
policy is developed for the men’s shoe making company. The main
characteristic of the shoe manufacturing is that the daily production
rate and processing times are highly volatile and subject to high
variances depending on the model and rapidly changing trends. The aim
of this study is to determine the optimum production policy over the
combinations of the models which will be produced in daily working
schedule. A simulation study was developed to see at what degree the
variations of the models effect the throughput rate.
Key words: Shoe Manufacturing, Production Analysis, Simulation, Arena.
Introduction
system nor a simple business. It
The customized products such as requires high skill and a lot of diverse
footwear or clothing industry where knowledge in many aspects that may
customer’s taste and choices change affect the quality, the appearance and
rapidly according to fashion dictates are the functions of a shoe. The significant
known as labor-intensive products. Shoe thing is that it requires a lot of work
making is neither an easy production which makes shoe making as a typical
labor-intensive process.
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Under the major goal of this study, the manufacturing reveals relationships
production analysis of the shoe among the processes and provides to
manufacturing is recognized as a highly determine the impact on the throughput
important stage to understand the of the production.
characteristics of the production system
and to assess its behavior under The main objective of the thesis is to
alternative policies. Production and measure the effect of variable styles
process analysis are significant for the (models) on the output of a production
manufacturing companies to improve line. Because the daily production rate
their productivity and to optimize usage and processing times are variable
of the resources. It is obvious that, depending on the model, the simulation
manufacturing is a complicated system model will provide a sensitivity analysis
that involves sets of tasks, materials, of the efficiency on the throughput rate
resources, products, and information. By and resource utilization.
doing production analysis, there are This study will be based on the
advantages of understanding the way simulation modeling of the men’s shoe
the production is done, finding the manufacturing. After experimentation of
problems and the gapping between simulation model, the results will be
current performance and expected analyzed to carry out the main
targets. objectives of the production system
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These steps will be used to build out processes must be followed. These are:
simulation modeling of the shoe • Problem Formulation and
manufacturing company. The steps in a Solution Methodology
simulation study (Winston, 2004) are System and Simulation
shown in Figure 2. However, in some
studies these several distinct stages may
not be included; there can even be some
overlap between some of the stages.
Shoe Manufacturing
Figure 1: Process diagram for finished
shoes
Methodology • Specifications
• Data Collection
In order to carry out the simulation • Model Construction
study successfully, the structured
• Verification
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Southeast Europe Journal of Soft Computing Volume 1. Number 1 March 2012
• Validation models)
• Experimentation and Analysis • Mean resource utilization
• Presenting the Results and (measured as the per machine
Conclusions utilization)
• The flow time (completion time of
Hereby, these processes will be analyzed a shoes)
respectively. • Queue waiting time and number
of waiting in processes
Problem Formulation and Solution • Number of reworks.
Methodology
To determine the specific solution
The main constrains and assumptions
methodology, the parameter should be
which cause having problems in the
based on a question of “which will most
production plant can be determined as
likely give the most cost-effective
follow;
solution” (Kelton & Sadowski, 2004).
• Daily production schedule consist
of variety of the models by given
orders, Table 1: Time analysis of the shoe
• Daily production contains at manufacturing
least 4 different type models and
maximum 10, TIME ANALYSIS FOR MODEL : 359 DAY:1
• Some work stations have long Seq. Processes Nr of Setup Waiti Proce Total
Work Time ng ssing Time
processing time to finish an
ers time Time
entity, 1 Preparation 1 0,5 0 1 1,5
• Processing times differs related Coupling
to different type of models, 2 Toe-Puff 1 0,75 0,58 0,133 1,463
Back Part
• Combination of different models3 Molding 1 0,16 0,5 0,166 0,826
cause to reduce of production4 Insole 1 0,25 0,25 0,55 1,05
rate. Roughing
5 up 1 0,16 0,1 0,33 0,59
• There is no way to produce single6 Toe Lasting 1 0,5 0,16 0,7 1,36
model in a day. Heel/Side
7 Lasting 1 1,6 0,13 0,083 1,813
The main problem which arises from8 Ironing 1 0,5 0 2 2,5
given reasons is having variety of Scouring/
9 Roughing 2 0,78 0,25 1,5 2,53
models in a same day. Namely, if the 10 Gluing 1 0,6 2 1,4 4
daily production consists of 10 models,
11 Attaching 2 0,1 0,625 0,5 1,225
the production rate is decreasing when12 Finishing 4 0,25 0,25 2,5 3
it is compared with the minimum TimeFlow 21,857
variety. The complexity of production
causes also having excessive usage of
resources.
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) e
4 130 220
5 129 218 -0,007
6 124 210 -0,046
7 120 203 -0,076
8 118 200 -0,092
9 108 183 -0,169
10 107 181 -0,176
Total
Avg.
Prod 120 203
Figure 6: Total average waiting times
The least production is 107 made by and number of waiting uppers in queue
producing 10 different models. The
production rate has reduced by17%. The
average number of production is reached
by producing 118 pairs with 8 different
models. The changes of the daily
production rate by the variety of the
model are also depicted in Figure 6.
Figure 4: Changes of the daily
production rate by the variety of the When the number of different models of
model shoes or varieties increases the waiting
time of the next job becomes high. So the
queue length has also increased. By
producing of four different models of
shoes wait 105.89 min in the bottleneck
stations which is the gluing of the upper
and sole. The quantity of waiting jobs is
29 pairs in average. In the case of
working with maximum variety, the
waiting time increased 23% and the
number of waiting jobs has increased
around 35%. Although this ratio, in
some workstations both waiting time
In each workstation, as the number of and number of waiting jobs are 0. It
different models of shoes increase the directly seized and released by the
process time increases as well. The workstation.
second important thing is, the process
Table 4: Result summary of average
time of the “Gluing the uppers and sole”
reworks
rises rapidly due to long duration of the
Count Aver Half Min Max
process. This is can be called as
. Widt averag averag
“Bottleneck Station” which mean the
h e e
longest process time between the
Rework 8.90 2.25 5.000 16.000
workstation.
s 0
Figure 5: Process times of the variations The results obtained by the experiment-
in each workstation ation of the model represent that the
minimum number of defect after the 10
replications is 5 pairs of lasted uppers.
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Conclusion
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