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Manufacturing process flow improvements using simulation and sustainable manufacturing

Simulation techniques are important tools that are used by businesses to guide decision-making, identify problems and provide solutions. This paper examines the adoption of simulation models and lean manufacturing techniques into the manufacturing line of a company in order to improve the process flow and reduce waste. A number of simulation models were built for the purpose of replicating the manufacturing line of the company. Attempts were made on the models to improve the process flow and reduce waste by reallocation of labour and machine resources through the use of Witness simulation statistics, Yamazumi charts and cross supporting, and flow charts. The waste generated due to machine breakdowns was explored and resolved through proactive engineering solutions which were proposed to repair the major breakdowns. An assessment of the waste generated by the transportation of components was carried out and multiple solutions were identified through the use of simulation models. The simulation results show that a rearrangement of resources, through the use of simulation and lean manufacturing techniques, yielded advantageous economical results for the company in terms of an increase in output by 18%, a reduction in waste by 10%, and an improvement in process flow leading to better throughout. Further, it could be seen that the breakdowns of machines and the transportation of components resulted in losses to the revenues of the company which could have been avoided by using the suggested proactive solutions.