A simulation study to improve line balancing in manufacturing production line

Ahmad Syamsul, Ahmad Aiman Haziq (2024) A simulation study to improve line balancing in manufacturing production line. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Lean manufacturing, the waiting time is the type of waste in Lean and it create a bottleneck in line productioin. Line balancing is a method used in the sector to get rid of unnecessary waiting. Productivity can be greatly increased after system bottlenecks are located and fixed since production downtime will be reduced. The challenge facing manufacturing organisations today is finding solutions that would enable them to increase output and performance. For this reason, companies are seeking for fresh approaches to raise production line productivity. Lean manufacturing concepts are now being implemented into the organisations of expanding manufacturing enterprises. Solving production line productivity issues is crucial in the industrial sector. This study was carried out at PEPS-JV Sdn. Bhd.The case company has found that they are not paying enough attention to cycle time precision and that the operator workloads are uneven. Lean manufacturing methods will be used to make decisions in order to resolve this issue. Another tool to help researchers find solutions to production line bottlenecks is the lean tool line balancing. The purpose of this study is to carry out a line balancing analysis using WITNESS simulation software in order to enhance the productivity of the production line. The productivity of the new workstation design is examined using the WITNESS simulation software. Bottlenecks will be employed as the first step in the construction of a WITNESS simulation model that can be used to make strategic decisions about process optimisation. This model can benefit from the information required to make such a decision. Simulation can be used to analyse the impact of utilising the right lean tools on a manufacturing line. A manufacturing company's production line's overall productivity aims to capture the ideal future state for the manufacturing company. As a result, the production line was examined using the time study approach in this study, which also gave the production line a more useful selection tool. Overall, this study provides PEPS-JV Sdn. Bhd. and other manufacturing companies interested in maximising line balancing utilising cutting-edge simulation tools and Lean Manufacturing concepts with useful and actionable advice. Companies can successfully improve the efficiency of their manufacturing lines, achieve long-term competitive advantage, and streamline operations by utilising the study's findings.

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