Simulation-based Design of a Pull Material Supply System for Low Volume Unpaced Assembly Lines: A Case Study in the Aerospace Industry

To stay competitive, many industries have adopted the principles of lean manufacturing. A key principle is to implement pull control in production and material supply. In aerospace manufacturing, the large product size and low volumes result in significantly longer total task times and greater material demands in fewer overall stations. Consequently, the impact of material supply control is high, and its detailed evaluation is imperative. This paper presents a case study of the development of a pull principle for the material supply at a manufacturer of landing flaps, which comprised two major phases. First, a pull principle that enables minimization of work in process (WIP), particularly on the shop floor, was developed. Second, through the application of a discrete-event simulation study, optimal parameter settings were identified, and the developed concept was validated on a detailed operational level. Concept development has shown that the CONWIP principle is suitable for low volume environments with similar material demand characteristics as the landing flap assembly. The simulation study showed that a significant reduction of WIP without additional demands on logistics processes is possible.