Throughput analysis in automotive paint shops: A case study

Jingshan Li

doi:10.1109/TASE.2004.829431

Throughput analysis in automotive paint shops: A case study

Jingshan Li

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

63 Citations (Scopus)

Abstract

In this paper, an overlapping decomposition method is used to estimate the throughput of a production system with multiple rework loops. The idea of the method is to decompose the system into a couple of serial lines and modify the parameters of overlapping machines to accommodate the effects of other lines. Using this method, the throughput of an automotive paint shop is analyzed and continuous improvement procedures are described. Note to Practitioners - Painting is an important element of vehicle production. A paint shop has been a system bottleneck in many automotive assembly plants due to its complexity. Fast and accurate analysis of its system throughput is important for design and continuous improvements. This paper introduces an iterative method to analyze the performance of paint shop type production systems, i.e., systems with multiple rework loops. The method has obtained good results in both theoretical study and applications on the factory floor. In addition, a case study at an automotive paint shop is introduced and continuous improvements process to identify and eliminate system bottlenecks is described. The presented method can also be applied to other production systems with similar structures.

Original language	English
Pages (from-to)	90-97
Journal	IEEE Transactions on Automation Science and Engineering
Volume	1
Issue number	1
DOIs	https://doi.org/10.1109/TASE.2004.829431
Publication status	Published - Jul 2004
Externally published	Yes

Bibliographical note

Publication details (e.g. title, author(s), publication statuses and dates) are captured on an “AS IS” and “AS AVAILABLE” basis at the time of record harvesting from the data source. Suggestions for further amendments or supplementary information can be sent to [email protected].

Funding

This work was supported by the National Science Foundation Engineering Research Center for Reconfigurable Machining Systems under NSF Grant EEC95-92125 and by the the Center’s industrial partners.

Research Keywords

Overlapping decomposition
Paint shop
Rework loop
Throughput analysis

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title = "Throughput analysis in automotive paint shops: A case study",

abstract = "In this paper, an overlapping decomposition method is used to estimate the throughput of a production system with multiple rework loops. The idea of the method is to decompose the system into a couple of serial lines and modify the parameters of overlapping machines to accommodate the effects of other lines. Using this method, the throughput of an automotive paint shop is analyzed and continuous improvement procedures are described. Note to Practitioners - Painting is an important element of vehicle production. A paint shop has been a system bottleneck in many automotive assembly plants due to its complexity. Fast and accurate analysis of its system throughput is important for design and continuous improvements. This paper introduces an iterative method to analyze the performance of paint shop type production systems, i.e., systems with multiple rework loops. The method has obtained good results in both theoretical study and applications on the factory floor. In addition, a case study at an automotive paint shop is introduced and continuous improvements process to identify and eliminate system bottlenecks is described. The presented method can also be applied to other production systems with similar structures.",

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PY - 2004/7

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N2 - In this paper, an overlapping decomposition method is used to estimate the throughput of a production system with multiple rework loops. The idea of the method is to decompose the system into a couple of serial lines and modify the parameters of overlapping machines to accommodate the effects of other lines. Using this method, the throughput of an automotive paint shop is analyzed and continuous improvement procedures are described. Note to Practitioners - Painting is an important element of vehicle production. A paint shop has been a system bottleneck in many automotive assembly plants due to its complexity. Fast and accurate analysis of its system throughput is important for design and continuous improvements. This paper introduces an iterative method to analyze the performance of paint shop type production systems, i.e., systems with multiple rework loops. The method has obtained good results in both theoretical study and applications on the factory floor. In addition, a case study at an automotive paint shop is introduced and continuous improvements process to identify and eliminate system bottlenecks is described. The presented method can also be applied to other production systems with similar structures.

AB - In this paper, an overlapping decomposition method is used to estimate the throughput of a production system with multiple rework loops. The idea of the method is to decompose the system into a couple of serial lines and modify the parameters of overlapping machines to accommodate the effects of other lines. Using this method, the throughput of an automotive paint shop is analyzed and continuous improvement procedures are described. Note to Practitioners - Painting is an important element of vehicle production. A paint shop has been a system bottleneck in many automotive assembly plants due to its complexity. Fast and accurate analysis of its system throughput is important for design and continuous improvements. This paper introduces an iterative method to analyze the performance of paint shop type production systems, i.e., systems with multiple rework loops. The method has obtained good results in both theoretical study and applications on the factory floor. In addition, a case study at an automotive paint shop is introduced and continuous improvements process to identify and eliminate system bottlenecks is described. The presented method can also be applied to other production systems with similar structures.

KW - Overlapping decomposition

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KW - Rework loop

KW - Throughput analysis

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DO - 10.1109/TASE.2004.829431

M3 - RGC 21 - Publication in refereed journal

SN - 1545-5955

VL - 1

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EP - 97

JO - IEEE Transactions on Automation Science and Engineering

JF - IEEE Transactions on Automation Science and Engineering

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Throughput analysis in automotive paint shops: A case study

Abstract

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Research Keywords

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