Authors:
Nuria Rosillo Guerrero
1
;
Nicolás Montés Sánchez
1
;
Antonio Falcó Montesinos
1
;
Eduardo Garcia Magraner
2
and
Judith Vizcaino Hilario
2
Affiliations:
1
Department of Mathematics, Physics and Technological Sciences, University CEU Cardenal Herrera, C/ San Bartolome 55, 46115 Valencia, Alfara del Patriarca, Spain
;
2
Ford Spain, Poligono Industrial Ford S/N, 46440 Valencia, Almussafes, Spain
Keyword(s):
Industry 4.0, Manufacturing Maps, Petri Nets, Miniterms, Optimal Pathfinding Algorithm, Optimal Manufacturing Sequence.
Abstract:
In this article, we present an innovative application of manufacturing maps, specifically combining Petri Nets and Miniterms. Our proposed algorithm enables the determination of an optimal manufacturing sequence based on real-time information from the manufacturing line. The primary objective of this algorithm is to minimize the disparity in cycle times between different models, aiming to minimize the duration of workstations being stopped or blocked. This optimization leads to a reduction in total production time, accompanied by various benefits such as energy savings and increased production. To validate our approach, we implemented the algorithm using manufacturing maps and applied it to the 8XY line—a multimodel welding line located at the Ford factory in Almussafes, Valencia. We conducted simulations using actual production data from the Ford factory, considering three different types of order: random, optimal, and unfavorable. The goal was to compare the production time for eac
h sequence. The results obtained from the simulations demonstrated a significant time improvement when employing the optimal sequence, as outlined in the article. A comprehensive analysis of the three sequences studied is provided. As a future direction of this research, we intend to explore additional applications that can leverage manufacturing maps for production line optimization. For instance, we plan to investigate the determination of optimal sequences for anomalies, where improvements in the line to reduce cycle time could yield greater profitability. Moreover, we aim to explore how production lines can be dynamically rebalanced in real-time to achieve energy savings and other advantages. These potential extensions highlight the versatility and practical implications of manufacturing maps in enhancing production line efficiency.
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