Presented in this thesis is a simulation-based design & analysis procedure for flow-line manufacturing systems. Based on the proposed procedure, an overhead conveyor system(OCS) is designed and analyzed. In the proposed design process, which is based on the axiomatic design principles(Suh 1990), three "design domains" - a functional requirements(FR), a physical & operational domain defining design parameters(DP), and an evaluation & implementation domain defining performance measures(PM) - are identified and then optimal values of DPs satisfying the FRs are determined via a computer simulation.
In the case of the OCS, the FRs are the loading & unloading capacities and the ability to balance the job flows between the supply of the preceding station and the demand from the succeeding station. Major DPs include the velocity, length, lot sizes, and loading schedules of the conveyor system, while the amount of overflow and the utilization of handcars are regarded as major PMs. As a case study, a detailed simulation investigation was made for an OCS in an actual tire manufacturing line, in which the effects of lot size and loading schedule on the performance of the OCS are analyzed.
