Solving bottleneck at production line through simulation to enhance productivity at manufacturing company

Henry Sang, Levynia Imas (2022) Solving bottleneck at production line through simulation to enhance productivity at manufacturing company. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

In Lean manufacturing, waiting waste is important to stream and indeed is probably the second most critical waste among all seven wastes. Line balancing is a technique implemented in the industry to eliminate wasteful waiting. Growing manufacturing companies have begun to incorporate lean manufacturing ideas into their organizations. It is important in industry to solve productivity problems in the production line. This research was conducted at PEPS-JV Sdn. Bhd .Currently, the case company discovered that they are lack of attention to the accuracy of cycle time and have unequal workload among the operator. Decisions will be made by using lean manufacturing techniques to solve this problem. In addition, lean tool line balancing is another tool to support researchers to solve bottlenecks in production lines. The aim of this study is to conduct a line balance study using Arena simulation software to improve the smoothness of the production line and thus increase productivity. Real-time data will be collected in case companies and shown in histograms. To move towards IR4.0, Arena simulation software is used to verify the productivity of the new workstation design. An Arena simulation model that can be used to make strategic decisions about process improvement will be built using bottlenecks as a basic step to solve problems in a productivity production line. This model can take advantage of the facts needed to make such a decision. The effect of using appropriate lean tools on a production line can be usefully analyzed through the use of simulation. The overall productivity produced by a manufacturing company's production line attempts to represent the manufacturing company's ideal future situation. As a result, the time study methodology used in this study to analyze the production line and provide it with a more effective selection tool. At the end of this study, a comparison of the results of the existing production line system and the new production line in the simulation model after the implementation of corrective actions shows that the productivity of product production has increased by 11.7% if reduced workstations and 2.5% increased if operator 2 does work on workstation 2. In this research, using the method of line balancing and Arena simulation is the best to solve the problem of bottlenecks issue that occurs in the production line. The proposed solution is a reduced workstation because the percentage productivity of product production is higher compared to the second one.

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