Design of experiments for the analysis of the effects of pallet arrival patterns and maintenance policies on FMC productivity

This paper analyses the effects of various maintenance policies and part arrival patterns on the performance of a flexible manufacturing cell (FMC). A simulation analysis coupled with design of experiments is utilised in the study. In particular, the design of experiments includes maintenance policy as a factor with five levels and part release patterns as a factor with six levels. Effects of all the combinations of factors on the productivity of a typical FMC system are analysed using a simulation modelling approach. The results show that both factors have significant effects on manufacturing cell productivity and equipment utilisations. Releasing the pallets with longest processing time first into the cell and introducing preventive maintenance (PM) combined with corrective maintenance (CM) resulted in highest cell productivity. When a CM was started, it was found that the next scheduled PM should be combined with the CM if the time left to the next scheduled PM was 20% or less than the actual scheduled time.