Keiji Mitsuyuki

Manufacturing adapter of distributed simulation systems using HLA

In this research, a distributed simulation system to easily evaluate a very large manufacturing system by synchronizing several different simulators is developed. We designed the distributed simulation system using the High Level Architecture (HLA) as the IEEE1516 standard. A manufacturing adapter to connect manufacturing system simulators with HLA using a plug-in style is proposed. The developed distributed simulation system is confirmed using a case to evaluate a hypothetical manufacturing system which produces motors. Three major commercial based manufacturing system simulators, QUEST, SIMPLE++, and GAROPS, are connected using the developed manufacturing adapter. The storage model method to connect simulation models and synchronize the simulators is used in the case study. A case study is then carried out to evaluate the performance of the cooperative work.

The development of an object-oriented simulation system based on the thought process of the manufacturing system design

The purpose of this research is to develop an integrated evaluation environment for manufacturing system designs. In this paper, we analyzed the thought process of manufacturing system design, and proposed a manufacturing system model for planning and evaluation by using a thought process model. The model evaluates a manufacturing systems design from the abstracted design phase to the detailed design. Finally, a prototype system for simulation using an object-oriented methodology was developed and implemented for a flow shop type manufacturing system design applying the proposed simulation model.

Manufacturing System Design Simulator based on Facility Life Cycle Model

Recently, when designing manufacturing systems to reduce manufacturing costs, the facility life cycle which includes from function design to disposal and reuse must be considered. First, the Facility Life Cycle simulator which is comprised of seven phases are defined to determine the five required phases of the simulator model. Second, by utilizing three simulator model stages, the system configuration constituents and attributes are determined. Third, MALIC (Manufacturing Life Cycle), a unique system configration is employed to examine three simulator structure layers. Forth, MALIC/FLS (Flow Line Simulator) confirms the results of the three simulator structure layers by employing a computer. Fifth, the application example employing MALIC/FLS confirmed the results of effectiveness. These results suggest that by employing MALIC/FLS, manufacturing costs are reduced in each phase of the Facility Life Cycle. In the future, MALIC will be employed throughout the entire manufacturing system to reduce manufacturing costs and save resources.

Method and Tool for Design Process Navigation and Automatic Generation of Simulation Models for Manufacturing Systems

Manufacturing system designers should concentrate on designing and planning manufacturing systems instead of spending their efforts on creating the simulation models to verify the design. This paper proposes a method and its tool to navigate the designers through the engineering process and generate the simulation model automatically from the design results. The design agent also supports collaborative design projects among different companies or divisions with distributed engineering and distributed simulation techniques. The idea was implemented and applied to a factory planning process.

WORKPLACE TASKS DESIGN SUPPORT SYSTEM BY USING COMPUTER MANNEQUIN

ABSTRACT On designing manual operation processes, the 3-D computer simulation model of the workplace with a computer mannequin can help a process planner consider Kaizen ideas to improve workplace tasks. For using the 3-D computer simulation with the computer mannequin in practice, this paper proposes a new modeling system, which enables users to modify the workplace tasks easily and quickly. The system can record the time, the motion code based on MTM, and the posture of the computer mannequin integrally step by step while teaching those data to the computer mannequin. The recorded data regenerate the simulation semi-automatically, and the users remodel the manual operation process concentrating on only differences between the initial model and the improved model.

A Collaborative Rapid Analysis Method for Decision-Making in Assembly Line Design

Many highly accurate computer simulation tools have been developed for assembly line design, such as for simulation of assembly processes, but these tools require much input information and are generally utilized only in detailed design stages. This paper proposes a rapid analysis method for manual assembly line design, which can be utilized in the conceptual design stage. This method is based on a layout tool where design engineers can construct assembly line models using 2- and 3-D views. This method provides design evaluation techniques for multiple important criteria such as volume flexibility, visibility, and so on, using the layout data. Spatial evaluation and quantitative efficiency analyses can be simultaneously performed, which enhance collaborative decision-making in the conceptual design stage.Copyright

Operation Method for Multi-Types and Multi-Stages Kanban System Using Discrete Event Simulation

Many studies have been done to optimize the Kanban system as production control system. However, most of them can be effective on only limited conditions. Therefore, these studies have difficulties to be applied in practice. The purpose of this study is to propose the practical method to operate Multi-types and Multi-stages Kanban system using discrete event simulation. The method sets the number of Kanbans much larger than the estimated number on the simulation model. From the simulation result, the surplus inventory is found. By subtracting the surplus inventory from the maximum inventory, the necessary number of Kanbans and the average of inventory are determined. Also the changeover time is calculated from the simulation result. The performance of Kanban system can be measured through the average of inventory and the changeover time. The best plan to operate Kanban system is selected among many alternatives based on that performance. To confirm the effectiveness of the method, an actual test case is tried out.