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Simulation of Sensor Device Inspection Process
#Verification of Workforce Size #Operator Inspection #Collaborative Work (Man-Machine) #Labor Saving #Multi-skilled Workers
Model Overview
- Production Line Characteristics
- This is a workplace for inspection processes in a sensor device production plant.
- In the inspection process, various types of measurements and adjustments are performed.
- One adjustment task is divided into 10–12 detailed work steps.
- Detailed individual adjustment tasks include manual operations performed by operators and automated operations performed by equipment.
- Each operator is responsible for multiple machines.
- Operators transport items to the next piece of equipment for subsequent tasks.
- Since operators handle multiple tasks (various adjustment tasks and transportation), they must prioritize these tasks.
- Key Points
This production line (workplace) has five types of equipment for measurement and adjustment, totaling 12 units.
Manual measurement and adjustment tasks (fixed-position work) are assigned to operators, and each operator is responsible for multiple machines (multi-process and multi-machine handling).
This simulation model was created to verify:
How should operators be assigned (who handles what)?
How many operators are needed?
What equipment layout maximizes production efficiency?
This modeling was created using GD.findi MS.
It is a no-code production simulator that performs production simulations in a digital virtual space, providing powerful support for line design and process design.
Output Report Example
Compare the operational status of the current 7 workers with that of the improved 5 workers.
Current Worker Utilization Status
➡ Low utilization rate for tasks outside assembly processes
Worker Utilization Status After Improvement
・Number of workers: 7 -> 5 (Assembly process assignments unchanged)
・Assignments: All non-assembly processes become multi-skilled (all 3 assigned workers handle all processes except assembly)
➡ Production finished earlier (despite reducing headcount)
By not fixing worker assignments, we effectively utilized available workers and increased productivity.
Applicable Industries/Line Configurations
- Sensor device manufacturing (processes combining manual operations and automated processing)
- Lines aiming to improve productivity through multi-machine handling and multi-skilled operators, and promoting FA (Factory Automation)