This study selected two labor-intensive processes in harsh environments among domestic food production processes. It analyzed their improvement effectiveness using 3-dimensional (3D) simulation. The selected processes were the “frozen storage source transfer and dismantling process” (Case 1) and the “heavily loaded box transfer process” (Case 2). The layout, process sequence, man-hours, and output of each process were measured during a visit to a real food manufacturing factory. Based on the data measured, the 3D simulation model was visually analyzed to evaluate the operational processes. The number of workers, work rate, and throughput were also used as comparison and verification indicators before and after the improvement. The throughput of Case 1 and Case 2 increased by 44.8% and 69.7%, respectively, compared to the previous one, while the utilization rate showed high values despite the decrease, confirming that the actual selected process alone is a high-fatigue and high-risk process for workers. As a result of this study, it was determined that 3D simulation can provide a visual comparison to assess whether the actual process improvement has been accurately designed and implemented. Additionally, it was confirmed that preliminary verification of the process improvement is achievable.

조선소의 생산성은 제한된 자원을 얼마나 효율적이고 체계적으로 관리하고 사용하는가에 달려있다. 최근 들어 조선소에서는 생산관리 시스템을 고도화하기 위해 시뮬레이션 기법을 적용한 연구가 활발히 진행되고 있다. 본 논문에서는 시뮬레이션 기법을 생산관리에 적용한 조선소의 시뮬레이션 기반 생산 개념을 연구하였다. 이는 조선소 현장에서 경험과 직관에 의한 의사결정을 지양하고, 정량적이고 구체적인 데이터에 기반을 둔 개선방안을 확립할 수 있게 한다. 본 논문에서는 조선소의 생산 계획 중 선표 계획 영역에 대한 시뮬레이션 적용 연구를 수행하였으며, 이를 위해 조선소의 생산 계획 프로세스와 시스템을 분석하고 상용 시뮬레이션 소프트웨어를 이용한 시뮬레이션 시스템의 설계를 수행하였다. 이러한 시뮬레이션 시스템은 현재 조선소 생산관리 시스템의 운용환경을 고려하여 웹 환경에서 운용가능한 구조를 갖고 있으며, 이를 통해 조선소에서는 보다 손쉽게 생산 계획을 시뮬레이션하고 결과를 분석함으로써 보다 신뢰도 높은 생산 계획을 수립할 수 있을 것으로 기대한다.

In Production system, there are two ; One is the JIT system, which was developed by the Toyota corporation : the other is the MRP system, which was developed in the United States. The JIT system has been proved its effectiveness for production management system by many industries, however the effectiveness of its application in non-repetitive productions is yet uncertain unlike the MRP system. There has been many efforts in comparing and analyzing the usefulness and the limitation of those production systems. Accordingly, this study has focused its simulation model using MRP and JIT.