Track: Modeling and Simulation

Abstract

This paper aims to optimize a manufacturing process through creation of a simulation model that will be used to identify bottlenecks, restructure the layout and improve productivity. The paper also highlights the significance of process optimization in a manufacturing set up. Process optimizations strive to find the best solution for a process within the available constraints. Simulation is a collection of methodologies used to mimic the characteristics and behaviour of real system using computer software. Literature review was carried out to understand system dynamics and simulation.  A case study was conducted at a manufacturing company. An Arena simulation model representing the process under study was developed and analysed.  Various models were run and the results compared. The best model was developed that improved productivity through restructuring of the layout and minimization of the cycle times on the identified bottleneck stations. The simulation results showed that there was a vast difference on the amount of material input and the ATMs and Safes produced.  The limitation of this study was that it only focused on the production of two products in the case studied company.

Keyswords: Optimization, Simulation, modelling, Bottleneck and Productivity