System modeling and real-time simulator for highly model-mixed assembly systems

In recent years, the automobile industry is facing more challenge than ever dire to rapid model change requirements and demand fluctuations. Tradition al fixed-type production systems are less capable in coping with the rapid change, while flexible production systems can better meet the requirement o f low-volume production with model variations. Flexible machines integrated with model-mixed assembly lines form flexible assembly systems (FASs). In this paper, Colored Timed Petri Net (CTPN) is used to model a highly model- mixed automobile assembly system. Based on this CTPN model, a real-time sim ulator was developed along with different dispatching rules. Besides, the a lgorithm of balanced budget work standard (BWS) for a small batch productio n is developed for adjusting the loading balance of the operators in the hi ghly model-mixed assembly lines. The simulator can be used as an effective tool for developing scheduling strategies.