Abstract

This research aims to analyze footwear manufacturing assembly lines' performance and increase its production by maximizing the measurement of performances like throughput and resource utilization with a case study. A shoe model with 46 components has been selected from the case company. The study starts with VSM to visualize the process flow, identify the production status, and any potential alerts. A discrete event simulation model is used to analyze precisely the manufacturing system's actual performance without disturbing the real system. After analyzing the collected data using the Arena input analyzer, a simulation model was developed, verified, validated, and run for 40 replications. Six proposed alternative solutions have experimented with Arena simulation software, and the best alternative solution results in improvement of output from 191 to 278 and from 174 to 536, line balance efficiency from 68.3% to 90.1%, and from 17.6% to 76% in stitching and lasting assembly lines, respectively.