Design and modeling of Roll-to-Roll manufacturing system using simulation techniques

Roll-to-Roll (R2R) processing is a complex production system which involves discrete and continuous processes. Raw materials, in the form of rolls of functional film, go through their own unique routes of different process machines. This complexity makes it difficult to estimate and measure production performances and how well the performances will be a vital factor to determine the adoption of the new technology for a company. In this paper, these hybrid complex processes have been designed, modeled and simulated to obtain more accurate production performance data using simulation technique. Our simulation model is able to take parameters' inputs by the user (for example, machine speeds, order types, labor quantity, etc.), and give pertinent output data (for example, resource utilizations, order lead times, production throughputs, etc.) in a matter of minutes. This tool can also help to improve the R2R system performance by identifying optimal solutions through comparative analysis.