Improving a manufacturing process by mapping and simulation of critical operations

Purpose – This study aims to demonstrate the application of process mapping and simulation, using popular software tools, by examining a paper sheet cutting operation.Design/methodology/approach – An integrated approach is utilized to model a sheeting operation at Advance Agro, PCL, Thailand, a pulp and paper manufacturer. The sheeting operation is one of the most critical operations. The redesigned sheeting operation resulted in setup time reduction. This was carried out by studying the process map, data analysis, and simulation of the redesigned operation (using Visio, Excel and Arena software) before a real implementation at the manufacturing plant. The simulation of redesigned sheeting process showed increase in productivity and annual cost savings.Findings – Case experiences indicate that combining process mapping and data analysis with simulation is beneficial. The computer‐based integrated approach successfully reduces the risk of ineffectiveness of the redesigned critical manufacturing operation. ...