This study presents a discrete-event simulation analysis of precast concrete segment production using Arena software, with the aim of enhancing system efficiency and throughput. The production system was modeled to include concrete batching, mould filling, low-heat and high-heat curing, segment unloading, cooling, and final transportation to curing basins. Key performance indicators measured included the number of segment batches fed into the system, number of completed batches, total number of concrete segments produced, work-in-progress, average waiting times, and resource utilization. Validation against real production data showed less than 10% deviation, confirming model reliability. Simulation results for a 10-hour production period revealed that the low-heat curing chamber was the primary bottleneck, operating at 96% utilization and causing significant delays. Reducing curing residence times increased the total number of segments produced from 42 to 56, improving system throughput by 33%. Based on these findings, recommendations include expanding low-heat curing capacity, reducing curing times through accelerated techniques, increasing mould availability, implementing parallel processing, and optimizing batch scheduling. These strategies are expected to enhance production efficiency, reduce waiting times, and increase the overall output of concrete segments.

Keywords

Precast Concrete Segments, Discrete-Event Simulation, Arena Software, Production Efficiency and Bottleneck Analysis