v 1.5.
Research Objectives 5
1.6. Research Scopes
6 1.7.
Organization of the Thesis 6
2. LITERATURE REVIEW 8
2.1. Operation Management
8 2.1.1.
Production Planning and Control 9
2.1.2. Loading
12 2.1.3.
Transfer Batch Size TBS 24
2.2. Hard Disc Drive Manufacturing System
27 2.2.1.
Hard Disc Drive Manufacturing System Problems 28
2.3. Simulation
29 2.3.1.
Why Simulation 31
2.3.2. Simulation in Manufacturing
32 2.3.3.
Simulation Optimization 39
2.4. Multi Criteria Decision Making MCDM analysis
41 2.4.1.
Analytic Hierarchical Process AHP 42
2.4.2. Technique for Order Preference by Similarity to Ideal Solution TOPSIS 44
2.5. K-Chart
45 2.6.
Summary of Literature Review 48
vi
3. RESEARCH METHODOLOGY 50
3.1. Introduction
50 3.2.
Detail Company`s Background 50
3.3. Research Design
54 3.3.1.
Phase 1: Preliminary Study 56
3.3.2. Phase 2: Experimental Design 1
58 3.3.3.
Phase 3: Experimental Design 2 60
3.3.4. Documenting and Reporting
60
4. DEVELOPMENT OF MODELS AND EXPERIMENTS 62
4.1. Introduction
62 4.2.
Process Flow in Case Company 62
4.3. Conceptual Modeling
64 4.3.1.
Scope of the Model and Level of Details 65
4.3.2. Assumptions
67 4.4.
Model Data 67
4.5. Model Translation in ProModel® 7.5 Simulation Software
72 4.6.
Verification and Validation 90
4.7. Warm-up Determination
94 4.8.
Number of Replications 97
4.9. Experimentations
98 4.9.1.
Experimental Design 1 99
vii 4.9.2.
Experimental Design 2 113
5. RESULTS AND DISCUSSIONS 118
5.1. Introduction
118 5.2.
Results for Experimental Design 1 118
5.2.1. Result of Mathematical Model for Mixed-load Tester
118 5.2.2.
Results of Simulation Modeling 126
5.2.3. Results of Identification of the Best Scenario
130 5.3.
Results for Experimental Design 2 136
5.4. Summary of Experimental Results and Discussion
138 5.5.
Research Contributions 140
6. COCLUSIONS AND RECOMMENDATIONS 142
6.1. Conclusion
142 6.2.
Recommendations 144
REFERENCES 145
APPENDICES 163
viii
LIST OF TABLES
TABLE TITLE
PAGE
2.1 A Summary of Related Literature on Machine Loading Problem in Various Applications
18 2.2 Applications and categorization of simulation technique
35 3.1 The Historical Data Throughput
52 4.1 Scope of the Model
65 4.2 Level of Detail
66 4.3 Testing Time and Processing Time of Product T Standard Time
68 4.4 Current Mixed-load Tester Model
70 4.5 Testing Time Distribution of the Automatic Testing Process and
85 4.6 Input Quantity Distribution
89 4.7 Validation: Student T-Test for Throughput
91 4.8 Validation: Student T-Test for Tester Utilization
92 4.9 Results from Five Replications of Throughput Data
94 4.10 Scenarios of the Mixed-load Tester
104 4.11 Inputs for Calculating the Allocation Problem
105 4.12
Pairwise Comparison of Each Grade adopted by Chen et al., 2009 110
5.1 The Mixed Loading of Tester A for Scenario 1
120 5.2
The Hourly Loading of Tester A for Scenario 1 121
5.3 The Mixed Loading of Tester B for Scenario 1
123
ix
TABLE TITLE
PAGE
5.4 The Hourly Loading of Tester B for Scenario 1
124 5.5
The Scenarios of Mixed-load Tester with the Number of Testers 125
5.6 The Hourly Loading for All Product Families in Tester A and Tester B
126 5.7
Confidence Interval of the Six Scenarios 128
5.8 The AHP Results for Six Selected Scenarios
130 5.9
Normalized Decision Matrix 131
5.10 The Weighted Normalized Decision Matrix
132 5.11
Positive Ideal Solution 133
5.12 Negative Ideal Solution
133 5.13
Positive Ideal Separation 134
5.14 Negative Ideal Separation
134 5.15
The Relative Closeness to the Ideal Solution 135
5.16 The Comparison Results of AHP and TOPSIS
135 5.17
The Differences of Scenario 1 and Scenario 2 136
5.18 A Summary Confidence Interval and Prediction Interval for Throughput, System
WIP, and Tester Utilization for the Transfer Batch Size of 86 units 136
5.19 The Comparison Result: Current System versus Proposed Configuration
139
x
LIST OF FIGURES
FIGURE TITLE
PAGE
1.1 General Process Flow Diagram
3 1.2
Layout of Automatic Testing and Label Printing Processes 3
1.3 Average Tester Utilization: Current System versus Target
4 2.1
The General Process Flow of the HDD Manufacturing System 27
2.2 Research K-Chart
47 3.1
Back-end Process 51
3.2 The Operation Process
54 3.3
Research Design 55
3.4 The Details of the Hybrid Simulation Approach for Mixed-load Tester
61 4.1
Layout of the Automatic Testing and Label Printing Processes 63
4.2 Operation Process Flow Diagram
64 4.3
The Model Translation of the Base Model using the ProModel 7.5 Simulation Software
73 4.4
The Entities using the ProModel 7.5® Simulation Software 74
4.5 The Locations in ProModel 7.5® Simulation Software
75 4.6
The Locations of Sample Tester Group 76
4.7 The Resources in ProModel 7.5® Simulation Software
77 4.8
The Operator and Robot Paths for the Automatic Testing Process 78
4.9 Activity Cycle Diagram of Automatic Testing Process
78
xi
FIGURE TITLE
PAGE
4.10 The Routings of the Automatic Testing Process
79 4.11
The Routings using the ProModel® 7.5 Simulation Software 81
4.12 The Routings of Product T
82 4.13
The Routings of Product A, B, and S 83
4.14 The Entity Operation
84 4.15
The External File 85
4.16 Generate Testing Time of Product S
86 4.17
Export Data: Testing Time of Product S 86
4.18 The Entity Arrival using the ProModel 7.5® Simulation Software
87 4.19
The Auto::Fit of Distribution: Input Quantity of Product S 87
4.20 Summary of Goodness of Fit: Input Quantity of Product S
88 4.21
Goodness of Fit: Input Quantity of Product S 88
4.22 Export Data: Input Quantity of Product S
89 4.23
The Warm – Up Determination
97 4.24
The Number of Replications Determination 98
4.25 Model Input, Process, and Output
99 4.26
The Input, Process, and Output of Simulation Modeling 105
4.27 The Simulation Model of Scenario 1 for Experiment 1
108 4.28
AHP Model for Scenarios of Mixed-load Tester 110
4.29 Simulation Optimization Model
113 4.30
The Pallet Run 114
4.31 Macros Tool Box in the ProModel® 7.5 Simulation Software
115 4.32
Decision Variable Determination 115
4.33 Objective Function Determination
116
xii
FIGURE TITLE
PAGE
4.34 Simulation Parameter
117 5.1
The Proportion of the Mixed Loading in Tester A for Scenario 1 121
5.2 The Proportion of the Mixed Loading in Tester B for Scenario 1
124 5.3
The Average of Simulation Results for All Scenarios 127
5.4 The Improvement for system WIP
137 5.5
The System WIP in the SimRunner® Optimization Software 138
5.6 Utilization of Tester A and Tester B
139
xiii
LIST OF APPENDICES
APPENDIX TITLE
PAGE A
Historical Data of Throughput 163
B Verification Form
164 C
Data of Testing Time 166
D Historical Data of Throughput for Each Model
168 E
Historical Data of Input Quantity 169
F The Model Elements of Base Model
171 G
Historical Data of Tester Utilization 174
H Simulation Results for All Scenarios with Three Replication Runs
175 I
The Simulation Results of Scenario 1 177
J The Optimization Results
185 K
The Results of The System WIP in Different Transfer Batch Size 193
xiv
LIST OF ABBREVIATIONS
AHP Analytic Hierarchy Process
FIFO First-in-First-out
HDA Hard Disk Assembly
HDD Hard Disk Drive
MCDM Multi Criteria Decision Making
OM Operation Management
PPC Production Planning and Control
TBS Transfer Batch Size
TH Throughput
TOPSIS Technique for Order Preference by Similarity to Ideal Solution
WIP Work-in-Process
xv
LIST OF PUBLICATION
1. International Journal
