We present an ideal model of a typical vehicle assembly plant by generalizing selected case studies from the literature. The ideal model was extended to capture certain realities of material handling to obtain new scenarios. The Arena simulation platform was used to model both the base and scenario models.  Data and probability distribution used were obtained from specifications obtained from the literature and random projections. Using the number of outputs from the vehicle assembly plant, the base model and the scenarios were analyzed. Results of the sensitivity analysis of the scenario models confirm that as real-world systems emanate from the ideal systems for example by capturing material handling realities, the production or service outputs are constrained either positively or negatively. Thus, showing the need for understanding different configuration settings of material handling equipment when scaling up production outputs is desired. The simulation modelling and analysis employed are useful both as classroom illustrations on material handling, aid for engineering education and for other users in need of general understanding and applications of discrete event simulation modelling.