Productivity improvement using discrete events simulation

The increasing in complexity of the manufacturing systems has increased the cost of investment in many industries. Furthermore, the theoretical feasibility studies are not enough to take the decision in investing for that particular area. Therefore, the development of the new advanced software is protecting the manufacturer from investing money in production lines that may not be sufficient and effective with their requirement in terms of machine utilization and productivity issue. By conducting a simulation, using accurate model will reduce and eliminate the risk associated with their new investment. The aim of this research is to prove and highlight the importance of simulation in decision-making process. Delmia quest software was used as a simulation program to run a simulation for the production line. A simulation was first done for the existing production line and show that the estimated production rate is 261 units/day. The results have been analysed based on utilization percentage and idle time. Two different scenarios have been proposed based on different objectives. The first scenario is by focusing on low utilization machines and their idle time, this was resulted in minimizing the number of machines used by three with the addition of the works who maintain them without having an effect on the production rate. The second scenario is to increase the production rate by upgrading the curing machine which lead to the increase in the daily productivity by 7% from 261 units to 281units