Using simulation in layout verification of solar module assembly workshop

Abstract

Facility layout problem (FLP) contemplates the optimization of space utilization, costs, and material flow. Commercial simulation softwares are commonly used to validate layouts by simulating the real world material flow and production process. To validate a layout scenario of a solar module assembly workshop, a 3D simulation model is presented which was designed on VisualComponents software. To begin with, we introduce the layout characteristics and use the systematic layout planning (SLP) method to design the block layout of workshop. Then, we built components library which contains all the facilities needed in the production line, specifically conveyors, processing equipments, robots, buffers. Finally, we have established a simulation layout model using the components in the customized library according to the block layout, and configured the components which were allocated in the layout by setting the parameters and building the connection between components via signal. To improve the performance of the workshop, we have found the best work-in-process (WIP) value for the workshop and the optimal number of workers. Additionally, the layout model was used to test collision and reachability. It demonstrated the production process in a realistic simulation environment which helped in the sales process as well. The reusable component models we have built make it easy to build a layout within a short time and validate the effectiveness of the layout scenarios for any other projects.