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Effective bottleneck analysis through simulation: a Lean case study
Abstract
In this paper, the simulation is described as one of the best approaches for performing bottleneck analysis and process improvement. Further in the content, the bottleneck types are presented, the reasons for their occurrence as well as the methods for identifying the bottleneck in the process. The emphasis of this paper is the proposed methodology and the improvement and analysis of the bottlenecks using the simulation method. With the help of simulation software-Technomatix Plant Simulation, a production process for wooden chairs has been programmed for analysis. With the Bottleneck Analyzer tool, the process is analyzed and the bottlenecks are identified. The data obtained from each analysis were used to improve the model by experimenting with the basic model. From the experimentation process, a few more improved models have been obtained, each with increased productivity than the previous one.
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The problem of bottlenecks is a key issue in optimising and increasing the efficiency of manufacturing processes. Detecting and analysing bottlenecks is one of the basic constraints to the contemporary production enterprises. The enterprises should not ignore problems that significantly influence the efficiency of the processes. People responsible for the proper course of production try to devise methods to eliminate bottlenecks and the waiting time at the production line. The possibilities of production lines are limited by the throughput of bottlenecks that disturb the smoothness of the processes. The presented results of the experimental research show the possibilities of a computer simulation as a method for analysing problems connected with limiting the production capacity. A computer-assisted simulation allows for studying issues of various complexities that could be too work-consuming or impossible while using classic analytical methods. The article presents the results of the computer model analysis that involved the functioning of machinery within a chosen technological line of an enterprise from a sanitary sector. The major objective of the paper is to identify the possibility of applying selected simulation tool while analysing production bottlenecks. An additional purpose is to illustrate the subjects of production bottlenecks and creating simulation models. The problem analysis involved the application of the software Tecnomatix Plant Simulation by Siemens. The basic methods of research used in the study were literature studies and computer simulation.
The performance of a manufacturing or logistic system is determined by its constraints. Therefore, in order to improve the performance, it is necessary to improve the constraints, also known as the bottlenecks. Finding the bottlenecks, however, is not easy. We compare the two most common bottleneck detection methods, based on the utilization and the waiting time, with the shifting bottleneck detection method developed by us, for AGV systems. We find that the two conventional methods have many shortcomings compared to the shifting bottleneck detection method. In the example presented here, conventional methods are either unable to detect the bottleneck at all or detect the bottleneck incorrectly. The shifting bottleneck detection method not only finds the bottlenecks but also determines the magnitude of the primary and secondary bottlenecks.
Firms are facing very short and important innovation cycles, particularly in IT and Telecommunication sectors. Then a question appears: why do some innovations succeed whereas other fail. From offer’s point of view, a way could be to evaluate impacts of a decision to innovate for each of the actors involved in this product trajectory. Therefore the goal of such an approach is reducing high Innovation development risks by integrating the diverse stakes of life cycle actors and by helping design teams to integrate the evolution of some key environmental processes. We introduce in this paper the characteristics of the Innovation Process and Engineering Design Phase for high level innovations. In this framework, we propose an Innovation Valuation Model integrating strategic and tactic impacts in term of value and cost.
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