Balancing the production line by the simulation and statistics techniques: A case study

Abstract

A wide range of the real world problems in industries are related to misbalances of the production line and excessive Work in Process parts (WIP). Simulation is an effective method to recognize these problems with consuming least cost and time. Moreover, total system efficiency of a production line can be extremely improved by examining different solution scenario via the simulation techniques. In this research, we utilize the simulation technique founded upon the software Enterprise Dynamics (ED) for evaluating the cause of these problems and trying to find the improvement solutions in Sadid Pipe and Equipment Company (SPECO). Two parameters of diameter and thickness are important factors affecting the time of workstations. The effects of these factors on process time are evaluated by hypothesis tests. Two improvement scenarios have been presented. In the first scenario, the layout design of the factory has been improved with regard to production process and bottleneck station. In the second one, an essential improvement has been carried out by reduction in wastages. Regarding the accomplished simulations, it is concluded that it is possible to eliminate the existing bottleneck by implementing changes in the locations of production stations or reducing the waste in some stations. The improvements eventually result in balancing the production line. © Maxwell Scientific Organization, 2014.