Prolonged truck turnaround time (TTT) is a critical bottleneck in outbound logistics, leading to operational congestion, increased costs, and customer dissatisfaction. This study addresses this challenge by implementing an integrated methodology combining work study and discrete-event simulation (DES) at a food industry company in Saudi Arabia. The research followed a structured four-phase approach: (1) empirical data collection through time studies and historical records to establish a baseline; (2) data analysis to identify process patterns, bottlenecks, inefficiencies; (3) development and validation of a DES model using Arena software; and (4) proposal of evidence-based improvements evaluated through key performance indicators. The findings demonstrate that the validated model accurately replicated real-world operations and identified key inefficiencies. The proposed improvements revealed significant potential for enhancing efficiency, with the optimal scenario achieving a substantial reduction in average TTT and waiting time, alongside an increase in system throughput. This study confirms the value of integrating empirical work study with simulation to create a robust, data-driven framework for logistics enhacement. It provides managers with a practical and replicable model for diagnosing bottlenecks and validating solutions prior to implementation, thereby enhancing operational efficiency and supply chain resilience.
Bottleneck Identification and Process Improvement in Outbound Logistics: An Integrated Work Study and Simulation Framework
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