Performance analysis of vehicle assembly line using discrete event simulation modelling

Abstract

The purpose of this paper is to utilise simulation as a decision making tool in a complex manufacturing setup. A vehicle assembly line at an automobile company in India is modelled and analysed to help managers to identify the criticality of different parameters. Conveyor speed, operator fatigue and incoming material quality were selected from a pool of parameters which affect the line output. On the basis of design of experiments (DOE), experiments were carried out to capture the effect of input parameters on the line output. The results from these were further analysed using response surface methodology (RSM) and analysis of variance (ANOVA). The line output was found to be most sensitive to operator fatigue followed by incoming material quality and conveyor speed. This paper provides a structured approach to analyse the vehicle assembly line in an automobile company and provides a suitable tool to the management to analyse the complex functioning of a manufacturing system.