Validating the Existing Solar Cell Manufacturing Plant Layout and Pro-posing an Alternative Layout Using Simulation

Modeling and Simulation techniques are powerful tools for evaluating best layout option by analyzing key performance indicators of a given process. A simulation technique for layout validation has its own unique benefit because the element of risk associated is almost zero. By sensitivity analysis potential process improvement strategies can be identified, evaluated, compared and chosen in a virtual environment much before the actual implementation and this helps in better decision making.

The dissertation work undertaken was on

process improvement

(reconfiguring plant layout in order to achieve effective utilization of resources, cost reduction and throughput improvement) i.e. to identify ways by which the performance could be improved in the system by, simulating the manufacturing process and evaluating the effectiveness of the process in terms of machine, human and system performance to identify bottlenecks and provide means to eliminate these inefficiencies.

Initially relevant data required was collected verified and cleaned using various statistical tools. After building the initial model an “AS-IS” model evolved, as the results were presented and discussed highlighting the pit falls in the current layout which affects the performance of the plant with process owners. At the analysis stage various “WHAT-IF” scenarios were identified and evaluated so as to identify the best alternative depending upon the performance measures which have the most significant improvement.

This would, hence, become a prerequisite for management in arriving at a better decision after evaluation of various alternative results obtained from the simulation.