A simulation-based modelling approach for a production line with nested-loop work sequences

ABSTRACT

Critical for current situation analysis in lean initiatives, establishing standardised work can be challenging due to the intricacies involved in documenting complex routine work, mainly characterised by nested-loop work sequences. This study aims to extend the existing methods of establishing standardised work and analysing a production line for complex routine work. Novel concepts and terminologies are introduced, combining the existing methods into a modelling approach capable of addressing all complex features simultaneously. A standardised work sequence diagram is defined as a fundamental representation, forming the basis for a new simulation-based modelling approach. Described, validated, and applied through an industrial case study, the proposed approach is confirmed effective, achieving an average relative combined cycle time of 0.99, compared to the expected value of 1. The resulting redesign of standardised work significantly improves line efficiency from 53% to 79%, with a manpower reduction from 8 to 4 workers.

KEYWORDS:

• Discrete event simulation
• lean manufacturing
• line balancing
• standardised work
• operator assignment

Acknowledgments

The authors would like to thank Mr. Pongkith Woonwiriyakij and Mr. Pakpoom Siriwatanakorn from Parts Industry (1999) Co., Ltd. for explaining about the processes and helping collect data necessary to complete this work. The authors would also like to thank Mr. Kraiwut Tibma from Hitachi Sunway Information Systems for helping with the use of Tecnomatix Plant Simulation.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Data availability statement

The data that support the findings of this study are available from the corresponding author, T.T., upon reasonable request.

Supplementary material

Supplemental data for this article can be accessed online at https://doi.org/10.1080/17477778.2024.2311382

Notes

1. SimTalk is an internal scripting language of Tecnomatix Plant Simulation.

2. A frame is one of standard objects provided by Tecnomatix Plant Simulation for the purpose of encapsulation.