Abstract

This paper studied the enhancement of productivity in the lighting steel pole manufacturing process of a company facing issues with production rates not meeting customer demand. The primary causes of these issues are waste occurring in the process and inappropriate allocation of resources relative to production volumes. This study focuses on applying simulation techniques using Flexsim software, lean manufacturing principles, and waste reduction strategies as tools for improving the manufacturing process. These tools provide a virtual improvement framework before actual implementation, aimed at reducing time and costs associated with process enhancements. The objectives of this research are to create a realistic simulation model of the current manufacturing process and to develop this model further to propose improvement strategies for increasing the production output of lighting steel poles to meet target levels. In this study, three scenarios were generated plans for improving the production process were presented. Analysis from the simulation models indicated that the third improvement plan was the most suitable. The results demonstrate an increase in the production capacity of lighting steel poles from 40 poles per day to 55 poles per day, which is sufficient to meet current customer demands. Worker utilization increased 16%, and line balance efficiency increased 14%. Additionally, it achieved the lowest costs by reducing labor expenses by $343 per month due to a reduction of one worker. The developed model also provides a foundation for future alternative developments in response to changing customer demands and can be applied to other similar manufacturing processes.