Performance Evaluation Model for MMALs using multi-system variables through Discrete Event Simulation

Abstract

Nowadays, in current global competitive market era, all manufacturing organizations are endeavoring to integrate innovative process modeling and simulation-based performance methods to improve production capacity and efficiency. Several system changes are required for existing manufacturing operations to improve profit and maintain position in global business sectors. Increase in product demand require the transformation of traditional assembly lines to mixed model assembly lines in modern production systems. Manufacturing industries face many problems like long manufacturing lead times, bottlenecks, low-capacity utilizations and low productivity which impact the overall efficiency. leads to decline in process efficiency of the manufacturing industries. Various techniques are used to enhance the process efficiency in a mixed model assembly line e.g., mathematical modeling, heuristic approach, search algorithm approach and simulation modeling method etc. Among such techniques, simulation modeling is a wellaccepted approach for improving process efficiency. Discrete event simulation (DES) is a modeling method that reduces bottlenecks in the manufacturing process and ensures peak performance of the system. This research work uses DES to analyze and recommend viable options to enhance the production of a high technology parts manufacturing industry. The simulation model is developed by using ARENA ® Simulation software for a case study. Performance metrics are assessed for existing and proposed reconfigurable assembly lines with increased productivity and overall efficiency. The simulation model helps to find the essential performance indicators of the production assembly lines for the case study. The results are then compared with the goal of optimizing the workflow in existing assembly lines and increasing the production capacity.