Using lean principles & simulation for productivity improvement: the case of a ceramic industry

In this work is illustrated an application of lean principles & simulation in order to increase shop-floor productivity at Vista Alegre Atlantis, SA, a well-known Portuguese ceramic industry. The case study reported in this paper is the outcome of the business internship program sponsored by the Department of Economics, Management and Industrial Engineering of University of Aveiro for the students in the Industrial Management and Engineering master program. A simulation model of the current operation of the finishing section was developed, along with the creation of a value stream mapping and the identification of waste, in order to ascertain its limitations and problems. The relevant operational performance measures such as throughput, work-in-process, and queue statistics, were analyzed to allow the proposal of a set of changes to the existing manufacturing operations. The outcome of the simulation study was taken into account by the decision-makers and the recommendations are being implemented.