Improving The Performance of The Footwear Manufacturing Industry Through Line Balancing and Simulation Modeling: A Case of Study in Anbessa Shoe Share Company
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Date
2023-03
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Addis Ababa University
Abstract
Manufacturing system modeling and performance analysis are methods for simulating and evaluating the performance of a production system. Modeling can be done using analytical, physical, or simulation techniques. Simulation is a more effective tool than analytical and physical methodologies for performance improvement studies because it is ideal for dynamic, discrete, and stochastic industrial systems.
Performance on the Anbessa shoe company's production lines has been evaluated and compared to the required level of performance. The most important performance metrics for cutting, stitching, and lasting lines were determined to be low efficiency, lengthy cycle times, high work-in-process levels, and low throughput rates. Processing times, machine failure rates, workspace distances, and manufacturing costs were only a few of the primary and secondary data points acquired.
During direct manufacturing line observation, processing speed was timed using a stopwatch. After this data analysis, an acceptable best fit from the available probability distribution was selected. Simulator models were developed, examined, validated, and assessed using Arena 14.0. Utilizing the opt-hunt software, which searches simulation models for the optimum solutions and generates a cost-benefit analysis for the proposed model, optimization models were constructed. Line balancing processes should be used to reduce workstations and production costs, one of the research's primary targets, in order to save 227,000 EB each month.
When the simulation model's output was finally reviewed, it was discovered that an unbalanced assembly line and a lack of organized workstations were to blame for the manufacturing lines' unsatisfactory performance. As a result, the cutting, stitching, lasting, and finishing efficiency of the recommended models improved by 7%, 3.45%, and 4.1%, and the company's gross profit climbed by 12% as a result. The competitiveness of a company can be greatly increased by the results of the suggested methodology.