Simulation Modeling and Performance Analysis of Production Schedule of Polymer Dispersion Plant with Limited Storage Tank

Abstract

Scheduling is a crucial point in the manufacturing process of Polymer Dispersion in a Polymer Dispersion Plant, especially for a plant that has a limited amount of storage tank. The optimization of scheduling is needed to avoid any bottleneck and achieve the optimum flow time and production cost by simulation modeling with Discrete Event Simulation. The best scenario on assigning and sequencing the product to be produced within the horizon of time can be observed. In this study, we analyze scheduling performance by testing all factors with two criteria: average product flow time and the cost of production. We conduct three phases process in this frame fork. In the first phase, we create the design of experiments to state the pre-defined process factor that affects the performance criteria. We make a simulation model of the Polymer dispersion plant based on the actual data and the second phase. The last phase calculates the aggregate of two performance criteria with Grey Relational Analysis to determine the best scenario. Based on the analysis in this study, among the other factors, the quantity rule and the reaction time rule have the most significant effect on the performance of production scheduling in the chemical plant, which the Polymer Dispersion Plant represents.