Optimizing throughput, WIP, and cycle time: A case study of utensils manufacturing shop floor

Abstract

The development of simulation models for improving performances is trendy in manufacturing industries. This paper presents simulation model for evaluating and improving performances of a utensils manufacturing plant. Internal benchmarking is employed for comparison under exactly similar conditions. The data of all input variables is collected and statistical models for each process is developed using Arena input analyzer. The simulation model is then developed using SIMIO to optimize throughput, work-in-process, and cycle time. The experiments have been performed under various scenarios, i.e., at different values of the input parameters. The areas for improvement have been highlighted on the basis of results. Furthermore, best and worst case scenarios have been discussed in detail to provide insights for managerial performance improvements by (1) optimizing inter-arrival time, (2) increasing production rate, and (3) reducing the number of rejected parts without disturbing the existing setup of the manufacturing facility.