Title: A simulation-based multi-objective optimisation for critical parameters design of an automotive paint shop using design of experiments

Authors: Razieh Keshavarzfard; Vahid Tavakoli

Addresses: Department of Industrial Engineering, North Tehran Branch, Islamic Azad University Tehran, Iran ' Department of Polymer, Amirkabir University of Technology, Tehran, Iran

Abstract: Regarding the increasing demand for luxury cars throughout the world, the painting process in the automotive industry is one of the most important issues. Considering the need for improvement in production performance, quality and agile customer responsiveness, this paper aims to use simulation to present how we can eliminate bottlenecks, and measure the obtained quality enhancement and increase production quantity. Making modifications to an active production line for optimisation purposes is a challenging process if not impossible. Thus, a process simulation method can be suitable for studying the system. This research implements how to use simulation tools in a real paint shop in one of the largest automobile manufacturing companies in Iran. Also, optimisation is used to find the best responses to the changes in the controllable variables or critical parameters. The results show a 58% increase in production capacity and 60% decrease in waiting time of the product.

Keywords: design of experiments; DOE; parameter design; computer simulation; multi-objective optimisation.

DOI: 10.1504/IJPMB.2024.135755

International Journal of Process Management and Benchmarking, 2024 Vol.16 No.1, pp.81 - 90

Received: 05 Jun 2022
Accepted: 02 Sep 2022
Published online: 04 Jan 2024 *