This research paper presents capacity planning and optimization for a national painting company using customized
time and motion study, simulation modeling and Lean manufacturing tools. The company currently facing large
delay in their production line due to a set of non-value added activities. Therefore, simulation modeling has been
used to identify the root causes of the problem in addition to time and motion study, value stream map, project
charter, cause and effect diagram and other tools. Thorough investigations, the root causes of the problems have
been identified and a new material handling method has been implemented in addition to two supermarkets (buffers)
within the production line. The proposed solutions minimized the process time from 6.24 hrs to 5.34 hrs and the
queue time from 2.5 hrs to zero.