Resumo:
Computational simulation together with optimization is an important tool in the
development of new projects, as the implantation of a new manufacture line. Simulation can
be used in the most varied phases of a new line development, however is in the project phase
where the most important decisions are taken. Questions as: How many operators are
necessary? Which is the regimen of work? Which is the necessary area? Which is the
productivity of the line? Are essential for cost formation of a new line and the precision of
these numbers can take the new line to the success or failure.
The present study approached the application of these techniques as a planning aid
tool in an auto parts factory, to verify the efficiency of the traditional method used by the
company where no advanced tool as the simulation is used.
The next chapters presented the methodology of these two techniques. Amongst them
we can detach the process mapping that beyond of being a basic tool for a good model
performance, assisted in the understanding of the process flow of the new line, allowing the
correction of errors that could lead the analysis to failure. The ProModel® simulation
package, that includes an optimization software based on Genetic Algorithms, the
SimRunner®, has been choose.
It can be concluded that the results reached through the simulation had been
significantly different from the ones reached by the traditional company methodology, mainly
in two aspects: labor was reduced in 45% and the productivity of the line was 4% above of the
foreseen one. These results had brought some benefits to the company like a new cost
formation that will make possible a reduction on manufactured products prices and also
making the new line more competitive.
Another benefit of these tools for the company is the project graphical visualization in
the static and dynamic form, what beyond enriching, facilitates the analysis with data and
more precise graphs.
