Using simulation to determine the batch size for I/O drawer test process in a high-end server manufacturing environment

Lawrence Al-Fandi, Faisal Aqlan

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

In this research, discrete-event simulation is used to study the I/O drawer test process in a high-end server manufacturing environment in order to identify the optimal batch size of the I/O drawers to be tested per driver. High-end server manufacturing environment is characterized by fast lead time and lengthy build process. Therefore, main components of the server, such as I/O drawers, are tested ahead of time (fabrication test) and stored in inventory as tested parts to be ready for prompt fulfilment of the customer orders. In this research, a simulation model is developed for the I/O drawer test process with a focus on batching the I/O drawers on testing. Different scenarios for the batch size are considered and a statistical comparison is performed against the current scenario used by the I/O drawer Fab test operators. Unlike the "one-piece flow" lean concept which encourages small batch size (even one), the results show significant savings in cycle time and energy consumption when the batch size is increased. This is attributed to the lengthy setup time of the I/O drawer testing process as using small batch sizes requires very short set-up time. The optimal batch size scenario results in cycle time savings by 20% which is equivalent to 8116 hours per year. Other savings include: electrical energy and less consumption of chilled water for the cooling units.

Original languageEnglish (US)
Title of host publicationFAIM 2014 - Proceedings of the 24th International Conference on Flexible Automation and Intelligent Manufacturing: Capturing Competitive Advantage via Advanced Manufacturing and Enterprise Transformation
PublisherDEStech Publications Inc.
Pages1017-1022
Number of pages6
ISBN (Electronic)9781605951737
StatePublished - 2014
Event24th International Conference on Flexible Automation and Intelligent Manufacturing, FAIM 2014 - San Antonio, United States
Duration: May 20 2014May 23 2014

Other

Other24th International Conference on Flexible Automation and Intelligent Manufacturing, FAIM 2014
CountryUnited States
CitySan Antonio
Period5/20/145/23/14

Fingerprint

Servers
Discrete event simulation
Testing
Energy utilization
Cooling
Fabrication
Water

All Science Journal Classification (ASJC) codes

  • Control and Systems Engineering
  • Artificial Intelligence
  • Industrial and Manufacturing Engineering

Cite this

Al-Fandi, L., & Aqlan, F. (2014). Using simulation to determine the batch size for I/O drawer test process in a high-end server manufacturing environment. In FAIM 2014 - Proceedings of the 24th International Conference on Flexible Automation and Intelligent Manufacturing: Capturing Competitive Advantage via Advanced Manufacturing and Enterprise Transformation (pp. 1017-1022). DEStech Publications Inc..
Al-Fandi, Lawrence ; Aqlan, Faisal. / Using simulation to determine the batch size for I/O drawer test process in a high-end server manufacturing environment. FAIM 2014 - Proceedings of the 24th International Conference on Flexible Automation and Intelligent Manufacturing: Capturing Competitive Advantage via Advanced Manufacturing and Enterprise Transformation. DEStech Publications Inc., 2014. pp. 1017-1022
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Al-Fandi, L & Aqlan, F 2014, Using simulation to determine the batch size for I/O drawer test process in a high-end server manufacturing environment. in FAIM 2014 - Proceedings of the 24th International Conference on Flexible Automation and Intelligent Manufacturing: Capturing Competitive Advantage via Advanced Manufacturing and Enterprise Transformation. DEStech Publications Inc., pp. 1017-1022, 24th International Conference on Flexible Automation and Intelligent Manufacturing, FAIM 2014, San Antonio, United States, 5/20/14.

Using simulation to determine the batch size for I/O drawer test process in a high-end server manufacturing environment. / Al-Fandi, Lawrence; Aqlan, Faisal.

FAIM 2014 - Proceedings of the 24th International Conference on Flexible Automation and Intelligent Manufacturing: Capturing Competitive Advantage via Advanced Manufacturing and Enterprise Transformation. DEStech Publications Inc., 2014. p. 1017-1022.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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Al-Fandi L, Aqlan F. Using simulation to determine the batch size for I/O drawer test process in a high-end server manufacturing environment. In FAIM 2014 - Proceedings of the 24th International Conference on Flexible Automation and Intelligent Manufacturing: Capturing Competitive Advantage via Advanced Manufacturing and Enterprise Transformation. DEStech Publications Inc. 2014. p. 1017-1022