A simulation based experimental design to analyze factors affecting production flow time

In this paper we analyze and evaluate the effects of some pre-defined process parameters on the performance of a manufacturing system. These parameters include two different plant layout types, namely functional layout (FL) and cellular manufacturing layout (CL), as well as scheduling rule, machine downtimes, batch sizes, and transporter (interstage transporters) capacities. First we employ simulation to evaluate the effects of these factors on the performance of the system and then conduct designed experiments to set the best levels for these factors. The performance evaluation function is defined in terms of the average flow time of all the part types through the manufacturing system. Arena 10.0 simulation software and SPSS 9.0 statistical package are used to measure the main effects and interactions between these factors. This work demonstrates that various manufacturing parameters should be considered jointly when designing or redesigning a facility because setting different levels for parameters can considerably affect the performance of a facility.