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ANALYSIS OF TRANSFER LINE WITH BUFFER STORAGE

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Manoj Gowda K

An automated transfer line is consisted of several workstations which are linked together by a material handling system where parts are transferred from one station to the next.

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MANOJ K 1MS16MCM09 M.TECH (CIM) TECHNICAL SEMINAR By M S RAMAIAH INSTITUTE OF TECHNOLOGY
Content 29 May 2018 2  Introduction  Automated transfer Line  Buffer storage  Workstation Breakdown Analysis  Performance Measurement  Case study 1  Case study 2  References
Introduction 29 May 2018 3  An automated transfer line is consisted of several workstations which are linked together by a material handling system where parts are transferred from one station to the next  No internal parts storage  one station breaks down, all other stations on the line are affected.  The other stations will be forced to stop for one of two reasons:  Starving of stations  Blocking of stations.
Automated transfer Line 29 May 2018 4  Multiple workstations linked together by a material handling system to transfer parts from one station to the next.
Automated transfer Line 29 May 2018 5  Suited for: • High product demand • Stable product • Long product life • Multiple operations  Benefits • Low direct labour content • Low product cost because cost • High production rates. • Production lead time and WIP are minimized. • Factory floor space is minimized.
Buffer storage 29 May 2018 6  Buffer storage system is a temporary storage location for goods being processed  It is located in between processing stations, whose processing times are significantly different.
Buffer storage 29 May 2018 7 Ex. The first operation requires only one shift to meet production requirements, while the second step requires two shifts to produce the same number of units. Buffer is needed between these operations to temporarily store the output of the first process.
Workstation Breakdown Analysis 29 May 2018 8 Common Reasons for Downtime in an Automated Production Line  Tool failures at workstations  Tool adjustments at workstations  Scheduled tool changes  Mechanical failure of a workstation  Mechanical failure of the transfer system  Insufficient space for completed parts  Preventive maintenance on the line  Worker breaks
Workstation Breakdown Analysis 29 May 2018 9  Upper-bound approach  In these cases, the work part is unaffected by the station malfunction, and there is no reason to remove the part.  F=n*P  Lower-bound approach  The brake tool must be replaced at the workstation, and the part must be removed from the line and cannot proceed to the next stations for additional processing.  F=1-(1-P)n
Performance Measurement 29 May 2018 10  Line efficiency  Downtime  Efficiency at stage  Line efficiency with buffer
Performance Measurement 29 May 2018 11  Rate of improvement obtained from buffer b  Case 1  Case 2
A Buffer Analysis in a Transfer Production Line. 29 May 2018 12  Abstract  Determination of buffer to increase line efficiency in a transfer line where several workstations are linked together by a conveyer. One of the common problems of a transfer line is minor stoppages. The buffer analysis using constant downtime distribution is employed in this paper.
29 May 201813 Experiment details  Separation of the line by a buffer based on the Frequency and average down time.  Calculate efficiency for buffer using constant downtime formulas and compare the efficiencies to select appropriate buffer size.  Graph of buffer size against line efficiency is plotted.  Slope of graph is determined to find appropriate buffer size.
29 May 201814 Graphs & Table
29 May 201815 The result of line efficiency at buffer size of 50 to 250 is summarized in table and plotted in figure. It can be seen from the graph that at 150 piece- buffer size is the most lucrative point Results & Conclusion
A Buffer Design for Mitigation Downtime Effect in an Automated Transfer Line 29 May 2018 16  Abstract  Design of buffer capacity between workstations to alleviate break down effect in an automated transfer line and increase the production rate
29 May 201817 Experiment details •Separation of the line by a buffer based on the Frequency and average down time. •Calculate efficiency for buffer using constant downtime formulas and compare the efficiencies to select appropriate buffer size. •Graph of buffer size against line efficiency is plotted.
29 May 201818 Graphs & Table
29 May 201819 Results & Conclusion The result of line efficiency at buffer size of 0 to 8 is summarized in table and plotted in figure. It can be seen from the graph that at 2 or 3 piece-buffer size is the most lucrative point. Numerical method to determine the appropriate number of buffer which is easy to obtain a solution.
References 29 May 2018 20  M. P. Groover, Automation, Production Systems and Computer- Integrated Manufacturing, 2nd ed. Prentice Hall International Inc. NJ, 1987, ch.18, pp. 565-595..  A Buffer Analysis in a Transfer Production Line, Yonlanan Chomnawung, Suksan Prombanpong and Chanakarn Klavohm, ICIEA 2016 (11th IEEE Conference on industrial Electronics and application)  A Buffer Design for Mitigation Downtime Effect in an Automated Transfer Line, S.Prombanpong, J. Kaewyu, N.Thanadulthaveedech, and M.Matwangsang, International Journal of Innovation, Management and Technology, Vol. 4, No. 1, February.  Modeling of a Two-Stage Merge Production with Buffer Storage, MEHMET SAVSAR, JKAU: Eng. Sci., vol. 4, pp. 67-81 (1412 A.H./1992 A.D.).  Buffer Management For Automated Material Handling Systems In Semiconductor Industries, Christian Fischmann, Fabian Böttinger, Roland Wertz and Christian Kunz, Proceedings 22nd European Conference on Modelling and Simulation ©ECMS.
29 May 201821 Thank you

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ANALYSIS OF TRANSFER LINE WITH BUFFER STORAGE

  • 1. MANOJ K 1MS16MCM09 M.TECH (CIM) TECHNICAL SEMINAR By M S RAMAIAH INSTITUTE OF TECHNOLOGY
  • 2. Content 29 May 2018 2  Introduction  Automated transfer Line  Buffer storage  Workstation Breakdown Analysis  Performance Measurement  Case study 1  Case study 2  References
  • 3. Introduction 29 May 2018 3  An automated transfer line is consisted of several workstations which are linked together by a material handling system where parts are transferred from one station to the next  No internal parts storage  one station breaks down, all other stations on the line are affected.  The other stations will be forced to stop for one of two reasons:  Starving of stations  Blocking of stations.
  • 4. Automated transfer Line 29 May 2018 4  Multiple workstations linked together by a material handling system to transfer parts from one station to the next.
  • 5. Automated transfer Line 29 May 2018 5  Suited for: • High product demand • Stable product • Long product life • Multiple operations  Benefits • Low direct labour content • Low product cost because cost • High production rates. • Production lead time and WIP are minimized. • Factory floor space is minimized.
  • 6. Buffer storage 29 May 2018 6  Buffer storage system is a temporary storage location for goods being processed  It is located in between processing stations, whose processing times are significantly different.
  • 7. Buffer storage 29 May 2018 7 Ex. The first operation requires only one shift to meet production requirements, while the second step requires two shifts to produce the same number of units. Buffer is needed between these operations to temporarily store the output of the first process.
  • 8. Workstation Breakdown Analysis 29 May 2018 8 Common Reasons for Downtime in an Automated Production Line  Tool failures at workstations  Tool adjustments at workstations  Scheduled tool changes  Mechanical failure of a workstation  Mechanical failure of the transfer system  Insufficient space for completed parts  Preventive maintenance on the line  Worker breaks
  • 9. Workstation Breakdown Analysis 29 May 2018 9  Upper-bound approach  In these cases, the work part is unaffected by the station malfunction, and there is no reason to remove the part.  F=n*P  Lower-bound approach  The brake tool must be replaced at the workstation, and the part must be removed from the line and cannot proceed to the next stations for additional processing.  F=1-(1-P)n
  • 10. Performance Measurement 29 May 2018 10  Line efficiency  Downtime  Efficiency at stage  Line efficiency with buffer
  • 11. Performance Measurement 29 May 2018 11  Rate of improvement obtained from buffer b  Case 1  Case 2
  • 12. A Buffer Analysis in a Transfer Production Line. 29 May 2018 12  Abstract  Determination of buffer to increase line efficiency in a transfer line where several workstations are linked together by a conveyer. One of the common problems of a transfer line is minor stoppages. The buffer analysis using constant downtime distribution is employed in this paper.
  • 13. 29 May 201813 Experiment details  Separation of the line by a buffer based on the Frequency and average down time.  Calculate efficiency for buffer using constant downtime formulas and compare the efficiencies to select appropriate buffer size.  Graph of buffer size against line efficiency is plotted.  Slope of graph is determined to find appropriate buffer size.
  • 15. 29 May 201815 The result of line efficiency at buffer size of 50 to 250 is summarized in table and plotted in figure. It can be seen from the graph that at 150 piece- buffer size is the most lucrative point Results & Conclusion
  • 16. A Buffer Design for Mitigation Downtime Effect in an Automated Transfer Line 29 May 2018 16  Abstract  Design of buffer capacity between workstations to alleviate break down effect in an automated transfer line and increase the production rate
  • 17. 29 May 201817 Experiment details •Separation of the line by a buffer based on the Frequency and average down time. •Calculate efficiency for buffer using constant downtime formulas and compare the efficiencies to select appropriate buffer size. •Graph of buffer size against line efficiency is plotted.
  • 19. 29 May 201819 Results & Conclusion The result of line efficiency at buffer size of 0 to 8 is summarized in table and plotted in figure. It can be seen from the graph that at 2 or 3 piece-buffer size is the most lucrative point. Numerical method to determine the appropriate number of buffer which is easy to obtain a solution.
  • 20. References 29 May 2018 20  M. P. Groover, Automation, Production Systems and Computer- Integrated Manufacturing, 2nd ed. Prentice Hall International Inc. NJ, 1987, ch.18, pp. 565-595..  A Buffer Analysis in a Transfer Production Line, Yonlanan Chomnawung, Suksan Prombanpong and Chanakarn Klavohm, ICIEA 2016 (11th IEEE Conference on industrial Electronics and application)  A Buffer Design for Mitigation Downtime Effect in an Automated Transfer Line, S.Prombanpong, J. Kaewyu, N.Thanadulthaveedech, and M.Matwangsang, International Journal of Innovation, Management and Technology, Vol. 4, No. 1, February.  Modeling of a Two-Stage Merge Production with Buffer Storage, MEHMET SAVSAR, JKAU: Eng. Sci., vol. 4, pp. 67-81 (1412 A.H./1992 A.D.).  Buffer Management For Automated Material Handling Systems In Semiconductor Industries, Christian Fischmann, Fabian Böttinger, Roland Wertz and Christian Kunz, Proceedings 22nd European Conference on Modelling and Simulation ©ECMS.