Bir Üretim İşletmesinde Simülasyon Yöntemi ile Darboğaz Analizi ve Sistem İyileştirmesi

Abstract

Achieving improvements in production processes requires analyzing the processes and identifying bottlenecks based on actual process data. Simulation is a widely applied method in analyzing the current state of production systems, identifying bottlenecks, developing alternative scenarios to improve throughput and resource utilization, and evaluating these scenarios’ performances. In this study, a discrete event simulation model of a stator production line of a company that produces electrical motors has been developed using AnyLogic software. The analyzed production line is a flow-type production line that consists of 8 machines and 11 operators. This study aims to detect the bottlenecks and determine a flow that maximizes resource utilization rates and minimizes inventory holding costs. The model parameters have been prepared with input analysis using the actual data from the past year of the line. The current state of the line revealed by running the simulation model has been analyzed. The findings have indicated that the winding machine is the bottleneck of the production line. The ideal production quantity of the winding machine has been determined by focusing on the productivity of the line and the utilization rates of resources to improve the system performance. Moreover, an alternative layout for the line has been suggested. Finally, the projected gains with this layout have been evaluated in terms of operator utilization rate.