Modeling And Simulation On The Manning Machine Ration Of Multiple-Cell Flexible Manufacturing System

In recent years, China labor cost is continuously and significantly increasing in most of provinces and industries, more and more companies (particular for semiconductor companies) are taking serious study on labor cost reduction in condition of reasonable tool utilization and normal production status so that the company can consistently keep the major competitor position in china as one member of biggest world manufacture center. Manning Machine Ratio (MMR) is a key measurement of operation efficiency of one operator; also its improvement is one of key ways to keep the company competition. In high mixture, low volume and extremely complex process flexible manufacturing system, the traditional static Excel model (embedding the MMR parameter, such as, lot size and cycle time) together with classic work study method focus only on single product. This method can not objectively reflect the actual labor productivity in critical machines, and it also will not be able to define the further productivity improvement opportunities. In additional, to maintain this kind of complicated and not duplicable static MMR models will take quite a lot of engineers'resource. At last, the result of this kind of classic study can not be fully communicated with key stake holders because of its unfriendly interface; therefore the result is normally not being convinced and implemented.This thesis addresses the modeling and simulation on the Man Machine Ratio (MMR) of multiple-cell flexible manufacturing system with a series of integrated research methods, including time and work study, scheduling model with corresponding rules, simulation modeling and its sensitivity analysis. The main results are as follows.1. Build a MMR simulation model with characters of simplification, intuition, flexibility, generalization and visibility. To overcome the difficulties faced by classical researches on MMR, some random factors, such as machine interfere problem, are integrated into the model. In addition, the model can be easily used in other fields because of its convenient input and output.2. Present the mechanisms by which the corresponding factors such as machine layout will affect the MMR according to the sensitivity analysis. Also our conclusions show that reducing the external processing times could reduce the partial labor requirement.3. Establish a scheduling model that can be used to deal with complex interfere issue between machines and labors. Some schedule rules are presented based on the scheduling model.4. The research results have been proved to be valid and the primary result has been applied successfully in the company. For example, the MMR of the company constraint station has been improved 33% without any capital investment and therefore the profit has been increased by these recommendations.Different from classical MMR calculation, our researches are based on the theory of method research, workshop dispatch and sensitivity analysis, and investigate the affect mechanism through considering the dynamic and stochastic factors. The research methodologies and techniques occurring in the thesis have the theoretic and applied significance for modern lean manufacturing, and have the instructive significance for China manufacturing to be competitive in the world.