System analysis, improvement and visualisation of a manufacturing workflow, using discrete-event simulation : A combination of discrete-event simulation and lean manufacturing

Abstract: This project has been initiated in cooperation with a Swedish manufacturing company. Due to increased demand and competition, the company wants to streamline its production process, increase the degree of automation and visualize specific workflows. By creating a frame of reference and a literature review, a theoretical basis for methods and concepts which has been utilized throughout the project has been obtained. With the help of the identified methods and methodologies, a current state analysis was performed. Using traditional Lean tools such as Genchi genbutsu, Ishikawa diagram and a 5-why analysis, in combination with time studies and interviews, the current state of the studied system was successfully mapped and analysed. With the help of the current state analysis, which served as a conceptual model, a simulation model of the current state was created in order to handle the large variety and the complexity of the system. The simulation model was validated and verified in order to ensure that it was “good enough” for the purpose of this project in the depiction of the real world system. During the experimental design, several improvement suggestions were created by utilizing methods such as brainstorming, Ishikawa diagram and a 5-why analysis. In a Kaizen event, onsite personnel had the opportunity to decide which suggestions that was fit for experimentation using simulation. With the result of the Kaizen event, experiments were performed in order to evaluate the proposed improvement suggestion. As a result, several new insights regarding improvements could be obtained, which provided several suggestions for an improved future state. Including a proposed automated cell. The analysis of the results did not entirely satisfy the aim of the project since certain factors could not be analysed, therefore the authors recommend that further studies are needed if proposed improvement suggestions are to be implemented.