Modeling and Simulation of Nonisothermal Plug Flow Reactor for Methanol Synthesis Via Methyl Acetate Saponification

The design of assembly lines for production operation is deemed crucial to ensure
optimal productivity and minimal work in progress. A case study involving investigation
of manufacturing assembly line is to be considered for computer based modeling using
WITNESS. The objective of this project is to model a manufacturing assembly line for 3
pin power plug using WITNESS and to conduct a sensitivity analysis that would
improve the production capability and output rate. The scope of the project is to conduct
the corresponding time study for manufacturing assembly line of 3 pin power plug
assembly including setup time and operation time. To conduct a simulation project using
WITNESS, there are several phases that to be concerned. The phases are established
objectives, scope and level of model details, data collection, structuring the model,
building the model, testing the model, experimentation, documentation, presentation of
result and implementation. The simulation result for manual assembly shows that the
number of finished product is 1332 pieces of 3 pin power plug in per day. The total time
taken for manual assembly for a 3 pin power plug is 43.2 sec (including handling time
and insertion time). The throughput time is 0.72 per minute. The time taken to insert the
part by using single station with one arm is 22 second while using two arms it's just
required 9 seconds. The throughput time for single station with one arm robot is 0.46
minute per pieces and for two arms is 0.25 minute per pieces. The result from simulation
shows great increased on the number of part produces when we introduce automated
assembly. In single station with one arm robot, 2085 pieces produces in daily. The
production of the plug increased double if compared with manual assembly. While the
double arm robot can produces 3839 pieces of power plug daily. From the result, it
shows that the single station system with two robot arm yield the best results. It can be
concluded that WITNESS is among one of the powerful tools to do a simulation for
assembly lines. Therefore further exploration on how to use the software should be
enhanced in order to fully utilize the benefit and capability of the simulation