Simulation and modelling is the process that aids in mimicking the behaviour of a real system for the purpose of conducting a study in order to understand operational processes and optimise the outcomes thereof by directly implementing the positive findings from the model in real life situations. The application of simulation and modelling using Arena simulation software has seen successful implementation based on its outcomes in many cases such as manufacturing process lines optimizations and in overall, improvement of supply chains in both manufacturing and service sectors. This study aimed at improvement of despatch work process line by making use of Arena simulation modelling as a tools for identifying areas of improvement of in a coal fly ash processing plant of a manufacturer situated in Sasolburg, South Africa. The manufacturer struggled with daily truck despatches, Arena simulation modelling software has revealed that key process waste was on amount of time spent on each despatch work process lines. With the current despatch process layout, 22 number of trucks are despatched within an 8 hour shift, time improvement estimations on despatch work process stages improved the number of trucks despatched to 30 which was 36% improvement, meanwhile simulation of proposed new despatch work process layout coupled with work process stages time interval estimate reduction showed an improvement of number of trucks from 22 to 40 which was 45%. It was recommended to the manufacturer to focus on either improving the time requirement within the work process stages using the current layout or opt for completely altering the layout and increase the length of the one out of three available despatch weighbridge which was 16 meters, thus to 24 meters in order to accommodate all types of trucks, particularly trucks with tankers and pub in order to improve daily number of truck despatches which is directly linked to sales.

Key words: Simulation modelling, Arena Simulation software, despatches, weighbridge