WAITING WASTE REDUCTION IN ASSEMBLY LINES USING HEURISTICS AND SIMULATION SCENARIOS

Abstract

ABSTRACT In this paper we propose a methodology based on clusterizations, simulation and a heuristic assignment with the purpose of identifying forklift drivers wich will send materials from the various storages throughout the production cells and thereby reduce waiting times due to material shortages in manufacturing plants that operate under Lean Manufacturing philosophy. Several clusters were compared, which were, obtained through empirical methods, hierarchical clustering methods and the Hungarian method. To implement and validate the proposed methodology, a simulation model was used, representing the production system for constant velocity joints, which consists of stores, productive cells and forklift drivers to send materials. In this model the performance of each of the clusters was tested and the loss percentage due to material shortage in each cell was calculated, depending on the cluster. Through the proposed methodology was possible to analyze the performance of different clustering strategies and determine which one is more efficient without the need of compromising business productivity.