scholarly journals Improving Distribution Process Using Lean Manufacturing and Simulation: A Case of Mexican Seafood Packer Company

2018 ◽  
Author(s):  
Julián I. Aguilar-Duque ◽  
Juan L. Hernandez-Arellano ◽  
Cesar Omar Balderrama-Armendariz ◽  
Guillermo Amaya-Parra ◽  
Liliana Avelar
Keyword(s):  
Simulation Model ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Model Development ◽  
Production Capacity ◽  
Mathematic Model ◽  
Global Market ◽  
Simulation Software ◽  
Market Demand ◽  
Work In Process

During the last decades, the production systems have developed different strategies to increase their competitiveness in the global market. In a manufacturing and services systems, Lean Manufacturing has been consolidated through the correct implementation of its tools. The present paper presents a case study developed in a Food Packer company where a Simulation Model was considered as an alternative to reduce the waste time generated by the poor distribution of operations and transportation areas for a product within the factory. As a matter of fact, the company has detected problems on the layout distribution that prevents to fulfill the market demand. In addition, the principal aim was to create a simulation model to test different hypothetical scenarios and alternative designs for the layout distribution without modifying its facilities. Moreover, the implemented methodology was based on classical models of simulation projects and a compendium of the manufacturing systems optimization by simulation process used during the last ten years. Also, a mathematic model supported by the Promodel ® simulation software was developed considering the company characteristics; along with the model development, it was possible to compare the production system performance from the percentage of used locations, the percentage of resources utilization, the number of finished products, and the level of Work in Process (WIP). Finally, the verification and validation stages were performed before running the scenarios in the real production area. The results generated by the implementation of the project represent an increase of 68% in the production capacity and a reduction of 5% in the WIP. In addition, both outcomes are associated with the resources management, which were reassigned to other production areas.

scholarly journals A STUDY ON THE IMPROVEMENT OF A LOCAL BOTTLE MANUFACTURING OPERATION: DEPLOYMENT OF LEAN PRINCIPLES AND DISCRETE EVENT SIMULATION

2020 ◽  
Author(s):  
Ezekiel Yorke ◽  
Boppana Chowdary ◽  
Jainarine Bansee
Keyword(s):  
Performance Indicators ◽  
Lean Manufacturing ◽  
Cost Benefit Analysis ◽  
Discrete Event ◽  
Cost Benefit ◽  
Key Performance Indicators ◽  
Global Market ◽  
Simulation Software ◽  
Actual System ◽  
Work In Process

Local manufacturing small and medium enterprises (SME) have faced continuous challenges in competing with manufacturing firms of scale on the global market. Factors such as the presence of a traditional organisational structure and inefficient utilisation of resources have contributed to the challenges faced by local SMEs in keeping up with regional and international competitors within the manufacturing sector. To investigate the aforementioned challenges, a case study was conducted on a local bottle manufacturing SME which sought to improve their system performance across their Plastic Injection Melding (PIM) operation. Using strategies in the form of lean manufacturing as well as ARENA® simulation software, the challenges identified within their operation were observed and mitigated using key performance indicators. Lean strategies such as Heijunka, Kanban and Six Sigma were utilised as possible methods of reducing waste within the existing simulation model. When comparing the key performance indicators from the simulation, findings highlighted improvements in the Work in Process (WIP) and Waiting Time (WT) by 84.78% and 98.03% for the entire operation. A cost-benefit analysis was carried out to identify the most financially feasible strategy in purchasing the resources that were required for the strategy’s integration into the actual system.

Evaluation of Lean Manufacturing Systems Using MADM and Fuzzy TOPSIS

2014 ◽  
Vol 592-594 ◽  
pp. 2628-2638 ◽  
Author(s):  
T.G. Arul ◽  
C. Arumugam ◽  
P. Parthiban
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Value Added ◽  
Fuzzy Topsis ◽  
Global Market ◽  
Triangular Fuzzy Numbers ◽  
Management Philosophy ◽  
Order Preference ◽  
Indian Industries ◽  
Real World Situation

Lean manufacturing is a management philosophy derived from Toyota Production System (TPS) which aims to increase the overall values of the product or service provided to the customer through elimination of non-value added activities. In the era of globalisation, to remain competitive in the global market, many medium and small sized Indian industries adopt lean manufacturing. This paper focuses on implementation of lean manufacturing in Indian MSMEs. To examine the implementation, attributes which influence lean manufacturing are obtained and industries’ performances on these criteria are rated. In this paper, the methodology selected from many of the multi criteria models is the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). In the actual real world situation, because of the unreliable nature of the information gathered, the attributes are often not absolute and are imprecise. These data can be considered as fuzzy and the aim of this paper is to adopt TOPSIS decision making method to problems with fuzzy data. The rating and weights of each data are expressed as triangular fuzzy numbers. These attributes are then normalized and the TOPSIS methodology is carried out to determine the effect of implementing lean manufacturing technique in an industry. The best industry is identified by fuzzy TOPSIS on the basis of performance towards the considered attributes is consistent with results identified by TOPSIS.

scholarly journals One Piece Production Principle Masters Global Market Challenges

2007 ◽  
Vol 3 (1) ◽  
pp. 51-62
Author(s):  
Gerhard Reichert ◽  
Dan Duse
Keyword(s):  
Manufacturing Systems ◽  
Agile Manufacturing ◽  
Global Market ◽  
Global Markets ◽  
Market Demand ◽  
Total Cost ◽  
Product Availability ◽  
New Methods ◽  
Design Changes ◽  
New Strategies

One Piece Production Principle Masters Global Market Challenges Successful companies in global markets must be innovative in product development and able to produce their products at lowest possible total cost, while highest quality and product availability in the markets is self evident. They must be able to manage violent market demand- and product design-changes with flexible and agile manufacturing systems [1]. These challenges ask, in the first place, for new strategies in the field of designing appropriate process technologies, production process structures and, as we will show, new methods and considerations for planning and controlling the sequence of product variants within production programs.

scholarly journals Scalability analysis of selected structures of a reconfigurable manufacturing system taking into account a reduction in machine tools reliability

2021 ◽  
Vol 23 (2) ◽  
pp. 242-252
Author(s):  
Arkadiusz Gola ◽  
Zbigniew Pastuszak ◽  
Marcin Relich ◽  
Łukasz Sobaszek ◽  
Eryk Szwarc
Keyword(s):  
Manufacturing Process ◽  
Machine Tools ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Production Capacity ◽  
Cost Effective ◽  
Simulation Software ◽  
Reconfigurable Manufacturing ◽  
Product Demand ◽  
The Impact

Scalability is a key feature of reconfigurable manufacturing systems (RMS). It enables fast and cost-effective adaptation of their structure to sudden changes in product demand. In principle, it allows to adjust a system's production capacity to match the existing orders. However, scalability can also act as a "safety buffer" to ensure a required minimum level of productivity, even when there is a decline in the reliability of the machines that are part of the machine tool subsystem of a manufacturing system. In this article, we analysed selected functional structures of an RMS under design to see whether they could be expanded should the reliability of machine tools decrease making it impossible to achieve a defined level of productivity. We also investigated the impact of the expansion of the system on its reliability. To identify bottlenecks in the manufacturing process, we ran computer simulations in which the course of the manufacturing process was modelled and simulated for 2-, 3-, 4- and 5-stage RMS structures using Tecnomatix Plant Simulation software.

scholarly journals Sensitivity and Feasibility Analysis of Citronella Oil Business

2020 ◽  
Vol 14 (2) ◽  
pp. 313
Author(s):  
Mohammad Prasanto Bimantio ◽  
Anthonius Dhinar Hasto Wardoyo
Keyword(s):  
Essential Oil ◽  
Production Capacity ◽  
Global Market ◽  
Local Market ◽  
Selling Price ◽  
Market Demand ◽  
Diverse Range ◽  
Citronella Oil ◽  
Product Sales ◽  
High Chance

Today, citronella essential oil business in Indonesia is fronting two major problems: a diverse range of product quality and fluctuated price. Meanwhile, the global market demand keeps increasing until 3–5% per year. This fact indicated that the citronella essential oil business was having a high chance of participating in the global market. This study aimed to analyze the citronella essential oil business feasibility as a “people-oriented-economy” activity and determine variables that affected the feasibility in implementing this business. Citronella essential oil is produced by a steam distillation process with a production capacity of 2,400 kg/year. The number of citronella essential oil international product sales was reaching 76% with the selling price of IDR 360,000/kg and reaching 24% on the local market with the selling price of IDR 180,000/kg, therefore the total of sales in 300 days/year was IDR 7,360,320,000. Based on this calculation the total of profit obtained in a year was IDR 99,463,383. An effort through managing the material and selling price sensitivity already done to maintain the BEP and B/C values. The increasing price was anticipated by managing the product selling price fraction, while the decreasing of the selling price anticipated by managing the market fraction.

Comparison of Connected vs. Disconnected Cellular Systems

2013 ◽  
pp. 37-52
Author(s):  
Gürsel A. Süer ◽  
Royston Lobo
Keyword(s):  
Adverse Effects ◽  
Manufacturing Systems ◽  
Cellular Manufacturing ◽  
Poor Performance ◽  
Simulation Models ◽  
Simulation Software ◽  
Cellular Systems ◽  
The Other ◽  
Work In Process ◽  
Make To Order

In this chapter, two cellular manufacturing systems, namely connected cells and disconnected cells, have been studied, and their performance was compared with respect to average flowtime and work-in-process inventory under make-to-order demand strategy. The study was performed in a medical device manufacturing company considering their a) existing system b) variations from the existing system by considering different process routings. Simulation models for each of the systems and each of the options were developed in ARENA 7.0 simulation software. The data used to model each of these systems were obtained from the company based on a period of nineteen months. Considering the existing system, no dominance was established between connected cells vs. disconnected cells as mixed results were obtained for different families. On the other hand, when different process routings were used, connected system outperformed the disconnected system. It is suspected that one additional operation required in the disconnected system as well batching requirement at the end of packaging led to poor performance for the disconnected cells. Finally, increased routing flexibility improved the performance of the connected cells, whereas it had adverse effects in the disconnected cells configuration.

Comparison of Connected vs. Disconnected Cellular Systems

2012 ◽  
pp. 663-678
Author(s):  
Gürsel A. Süer ◽  
Royston Lobo
Keyword(s):  
Adverse Effects ◽  
Manufacturing Systems ◽  
Cellular Manufacturing ◽  
Poor Performance ◽  
Simulation Models ◽  
Simulation Software ◽  
Cellular Systems ◽  
The Other ◽  
Work In Process ◽  
Make To Order

In this chapter, two cellular manufacturing systems, namely connected cells and disconnected cells, have been studied, and their performance was compared with respect to average flowtime and work-in-process inventory under make-to-order demand strategy. The study was performed in a medical device manufacturing company considering their a) existing system b) variations from the existing system by considering different process routings. Simulation models for each of the systems and each of the options were developed in ARENA 7.0 simulation software. The data used to model each of these systems were obtained from the company based on a period of nineteen months. Considering the existing system, no dominance was established between connected cells vs. disconnected cells as mixed results were obtained for different families. On the other hand, when different process routings were used, connected system outperformed the disconnected system. It is suspected that one additional operation required in the disconnected system as well batching requirement at the end of packaging led to poor performance for the disconnected cells. Finally, increased routing flexibility improved the performance of the connected cells, whereas it had adverse effects in the disconnected cells configuration.

scholarly journals Solution of Bottlenecks in the Logistics Flow by Applying the Kanban Module in the Tecnomatix Plant Simulation Software

2021 ◽  
Vol 13 (14) ◽  
pp. 7989
Author(s):  
Miriam Pekarcikova ◽  
Peter Trebuna ◽  
Marek Kliment ◽  
Michal Dic
Keyword(s):  
Lean Manufacturing ◽  
Business Processes ◽  
Software Tool ◽  
Transportation Systems ◽  
Simulation Software ◽  
Simulation Methods ◽  
Software Environment ◽  
Production Logistics ◽  
Pull System ◽  
Plant Simulation

The presented article deals with the issue of solving bottlenecks in the logistics flow of a manufacturing company. The Tx Plant Simulation software tool is used to detect bottlenecks and deficiencies in the company’s production, logistics and transportation systems. Together with the use of simulation methods and lean manufacturing tools, losses in business processes are eliminated and consequently flow throughput is improved. In the TX Plant Simulation software environment, using Bottleneck analyzer, bottlenecks were defined on the created simulation model and a method of optimizing logistics flows was designed and tested by introducing the Kanban pull system. This resulted in an improvement and throughput of the entire logistics flow, a reduction in inter-operational stocks and an increase in the efficiency of the production system as a whole.

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