Operations Status and Bottleneck Analysis and Improvement of a Batch Process Manufacturing Line Using Discrete Event Simulation

There are many product and process variations in the production systems of batch processing. Planning and executing such manufacturing operations can be a significant and challenging task. Discrete Event Simulation is an effective tool to analyze the moderate complex product and process variations and predict the operations status and bottlenecks of an existing manufacturing system, which is critical to the operation planning, execution, and improvement. This study simulates the first process stage of tire manufacturing in batch process involving product variation and process variants. The study analyses the operations status, bottlenecks, and the interdependence of the manufacturing activities between machines. In the simulation modeling and analysis, the efficiency of machines, reliability, quality, and setup time are considered. The simulation identifies the operation bottlenecks and WIP status, and proposes process changes for improved production efficiency. The simulation study helps schedule operations to reveal the requirement/necessity of changes or addition of the buffer based on buffer status analysis. The model can also verify the changes of machines for throughput improvement.