A Simulation Study for Implementing Color Rescheduling Storage in an Automotive Factory

Abstract

This article outlines a simulation study relating to the design and the implementation of color rescheduling storage (CRS) in an automotive factory. In a painting shop, the colors of vehicles are changed frequently according to the assembly schedule. When the color of a vehicle is changed, the cleaning process of the painting gun is necessary, which generates a cost. The major objective of CRS is to reduce the changeover cost in the painting process by grouping vehicles with the same color. In this article, a case study of CRS in an automotive factory is presented. The procedure for designing CRS is explained, and the storage/retrieval algorithms are suggested. The proposed system is verified using simulation models, and comparisons among alternatives are examined to determine the best design. The authors also investigate the effect of color distribution on the system performance measures.