Simulation modelling of tool crib to improve productivity of machining lines

Abstract

Consulta en la Biblioteca ETSI Industriales (8792)

[¿ng] Car manufacturers compete in their market focusing especially on reducing costs and increasing throughput, mainly through improvement of the performance of their production lines. However, ancillary processes complementing the lines (e.g. tool crib) also have a significant impact to the behaviour of the lines. Tool crib size has typically been overly estimated to absorb the disturbances on the lines it supplies. This thesis focuses on determining the right size and configuration of the tool crib to maximise the performance of the machining lines, and at the same time, to reduce the investment and inventory costs. The methodology adopted to carry out the research is based on simulation experimentation complemented by mathematical and empirical analyses. This thesis is a case-based research study, and the simulation tool used for modelling the case has been developed to include all the tooling elements. The research has focused on the following factors and how they affect the lines performance: availability of tool crib resources, tool inventory, different tool change strategies and link between tool crib and machining lines. Moreover, as extension to the study, the distributions of unexpected tool breakdowns have been built to consider their effect in the system. A simulation tool has been developed to support tooling engineers in planning, management and control of the tool crib. The results of the case study suggested the possibility of adjusting the resources inside the tool crib, giving a more accurate inventory level for the tools; and some recommendations with regards to other tool-change strategies. The research has also highlighted the impacts of tool breakdown to both the machining lines and the tool crib workload.