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Improvement of Eyeglass Lens Production Using Simulation Modeling and Dynamic Buffer Optimization

Daria Brun
Daria Brun
 y 
Cezary Szwed
Cezary Szwed
   | 18 dic 2021
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Publicado en línea: 18 dic 2021
Páginas: 195 - 208
DOI: https://doi.org/10.2478/fman-2021-0015
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© 2021 Daria Brun et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Figure 1

Production line with buffers (Source: Own elaboration)
Production line with buffers (Source: Own elaboration)

Figure 2

Iterative process of the optimization (Source: Own elaboration)
Iterative process of the optimization (Source: Own elaboration)

Figure 3

The process of curing eyeglass lenses (Source: Own elaboration)
The process of curing eyeglass lenses (Source: Own elaboration)

Figure 4

Simulation model of the curing process of spectacle lenses (Source: Own elaboration)
Simulation model of the curing process of spectacle lenses (Source: Own elaboration)

Figure 5

Experiments’ results (Source: Own elaboration)
Experiments’ results (Source: Own elaboration)

Figure 6

Percentage increase of the number of manufactured products as optimization results (Source: Own elaboration)
Percentage increase of the number of manufactured products as optimization results (Source: Own elaboration)

Figure 7

Efficiency graph for number of generations 20 and generation size 20 (Source: Own elaboration)
Efficiency graph for number of generations 20 and generation size 20 (Source: Own elaboration)

Choice of configuration for the best result (Source: Own elaboration)

Experiment B01 B02 B03 B04 B05 B06 B07 Objective
7 4 2 2 6 46 76 24 3884
12 4 2 2 6 46 76 24 3884
13 4 2 2 4 30 52 24 3884
15 2 4 2 8 52 52 16 3884
17 4 2 2 6 46 76 24 3884
18 4 2 2 4 30 52 24 3884
20 2 4 2 8 52 52 16 3884
22 4 2 2 6 46 76 24 3884
23 4 2 2 4 30 52 24 3884
24 4 4 6 6 40 52 96 3884
25 2 4 2 8 52 52 16 3884

Buffer capacity (Source: Own elaboration)

Buffer Capacity (pcs)
B01–B04 12
B05–B07 120

Processing times and machine capacities (Source: Own elaboration)

Station Processing time (min) Capacity (pcs)
A010 1:00 1
A020 10:00 12
A021 15:00 12
A022 15:00 12
A023 15:00 12
A024 15:00 12
A030 15:00 12
A031 15:00 12
A032 15:00 12
A033 15:00 12
A034 20:00 12
A040 6:00 12
A050 70:00 120
A060 80:00 120
A070 90:00 120

Experiments’ results (Source: Own elaboration)

Experiment Number of generation Size of generation Objective Buffer Capacity (decision variable) Running Time [sec]
B01 B02 B03 B04 B05 B06 B07
1 10 10 3856 2 6 4 8 86 46 48 62.3600
2 10 20 3872 4 2 2 6 46 76 18 132.3470
3 10 30 3858 4 2 4 4 32 52 10 192.9880
4 10 40 3878 2 4 2 8 42 52 96 252.0650
5 10 50 3870 2 4 2 8 52 56 26 330.5180
6 20 10 3868 2 6 4 8 36 76 48 126.0200
7 20 20 3884 4 2 2 6 46 76 24 270.6860
8 20 30 3882 4 2 2 4 30 52 10 395.2270
9 20 40 3878 2 4 2 8 42 52 96 525.5250
10 20 50 3880 2 4 2 8 52 56 16 656.1800
11 30 10 3868 2 6 4 8 36 76 48 199.4670
12 30 20 3884 4 2 2 6 46 76 24 409.8080
13 30 30 3884 4 2 2 4 30 52 24 604.6260
14 30 40 3882 4 4 6 6 38 52 96 781.3120
15 30 50 3884 2 4 2 8 52 52 16 937.6590
16 40 10 3878 2 4 4 8 38 76 48 276.7950
17 40 20 3884 4 2 2 6 46 76 24 549.0040
18 40 30 3884 4 2 2 4 30 52 24 794.0870
19 40 40 3882 4 4 6 6 38 52 96 1052.9440
20 40 50 3884 2 4 2 8 52 52 16 1287.4260
21 50 10 3878 2 4 4 8 38 76 48 347.1970
22 50 20 3884 4 2 2 6 46 76 24 693.6270
23 50 30 3884 4 2 2 4 30 52 24 980.5960
24 50 40 3884 4 4 6 6 40 52 96 1270.5940
25 50 50 3884 2 4 2 8 52 52 16 1538.1840

Number of products manufactured during the assumed period (Source: Own elaboration)

Variant B01 B02 B03 B04 B05 B06 B07 Objective
1 4 2 2 6 46 76 24 3448
2 4 2 2 4 30 52 24 3502
3 2 4 2 8 52 52 16 3504
4 4 4 6 6 40 52 96 3420

Percentage distribution of manufactured products (Source: Own elaboration)

Product Portion (%)
1.5 40
1.6 55
1.67 5

Constraints imposed on decision variables (Source: Own elaboration)

Buffer Lower bound Upper bound Step
B01–B04 2 12 2
B05–B07 2 120 2

Reduction of configuration for the best result (Source: Own elaboration)

Variant B01 B02 B03 B04 B05 B06 B07 Objective
1 4 2 2 6 46 76 24 3884
2 4 2 2 4 30 52 24 3884
3 2 4 2 8 52 52 16 3884
4 4 4 6 6 40 52 96 3884
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