Application of Taguchi Method to Analyze the Impact of Common Processes in Multistage Production System

This paper examines the optimum level of batch size in bottleneck facility and to analyze the effect of common processes on throughput and cycle time in a production system under uncertain situations created by machine breakdown. Few simulation models are carried out by comparing the existing model and proposed model of the production system in the company. The models are verified and validated with the historical data from the company. Taguchi approach for orthogonal array is used in designing experiment. The experimental settings are executed in WITNESS, a simulation package. The delivery performance, average production cycle time and production quantity for both line 1 and line 2 are examined. It is observed that the variation in level of common process in the system has significant impact on the production quantity and cycle time. The main contribution of this paper is determination of the optimal level of batch size in a bottleneck resource. This approach can be generalized to any multistage production system, regardless of the precedence relationships among the various production stages in the system.