Validation of the re-design of a manufacturing work cell using simulation

Simulation can be used to validate the design or redesign of any complex system before it is implemented. Validation evidence is obtained if the simulation demonstrates that the system operation corresponds to its design. This evidence includes comparing both detailed system behavior and performance measure values to those stated in the design. The application of simulation to validating the redesign of an injector assembly and calibration production area is discussed. Simulation is necessary to validate the initial estimate of cell throughput since a single worker must perform multiple operations at multiple workstations. The feasibility of the pattern of movement by this worker between stations must be demonstrated and alternative patterns assessed. Controls on the amount of work in process inventory in the cell must be validated. Modeling challenges unique to part movement using one-piece flow, work in process inventory control, and the movement of both workers and parts are discussed.