Simulation analysis for managing and improving productivity

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dc.contributor.author El-Khalil, Raed
dc.date.accessioned 2016-05-27T07:54:51Z
dc.date.available 2016-05-27T07:54:51Z
dc.date.copyright 2015 en_US
dc.identifier.issn 1741-038X en_US
dc.identifier.uri http://hdl.handle.net/10725/3891 en_US
dc.description.abstract Purpose – The current economic crisis increased the demand on management to improve process efficiency. The purpose of this paper is to identify and resolve inefficiencies within the car assembly system utilizing discrete simulation modeling and analysis in order to improve productivity at one of the original equipment manufacturers (OEM) body shops in North America. Design/methodology/approach – This research was driven by a manager’s recommendation from one of the Big Three (GM, Ford, Chrysler LLC) companies in order to improve operational performance. The data utilized in creating the simulation model was obtained from one of the assembly facilities that produce three different vehicles over a period of one year. All model simulation, inputs and outputs were discussed and agreed upon by facility management. Findings – The established base model was verified and validated to mimic the actual facility outputs indicating all process bottlenecks. Two model scenarios were considered: the first scenario focussed on the top bottleneck processes flexibility with a ROI of 497 percent, while the second considered changing the model mix percentage leading to a cost improvement of $1.6 million/annually. Research limitations/implications – The model only considered management decision on buffer sizes, batch size and the top bottleneck station alternatives to make improvements. Simulating improvements in labor efficiency, robots uptime, scrap root cause, and maintenance response to downtime where not considered. Practical implications – This paper indicated the importance of discrete simulation modeling in providing alternatives for improving process efficiency under certain financial limitations. Given the similarity of the automotive manufacturing processes among the various companies, the findings for this particular facility remain valid for other facilities. Originality/value – Investment cost and process improvement are currently the two biggest challenges facing operations managers in the manufacturing industry. This study allows managers to gain a broader perspective on discrete simulation ability to simulate complicated systems and present different process improvement alternative en_US
dc.language.iso en en_US
dc.title Simulation analysis for managing and improving productivity en_US
dc.type Article en_US
dc.description.version Published en_US
dc.title.subtitle A case study of an automotive company en_US
dc.author.school SOB en_US
dc.author.idnumber 201005172 en_US
dc.author.department Department of Information Technology and Operations Management (ITOM) en_US
dc.description.embargo N/A en_US
dc.relation.journal Journal of Manufacturing Technology Management en_US
dc.journal.volume 26 en_US
dc.journal.issue 1 en_US
dc.article.pages 36-56 en_US
dc.keywords Process efficiency en_US
dc.keywords Automotive industry en_US
dc.keywords Productivity en_US
dc.keywords Simulation en_US
dc.identifier.doi http://dx.doi.org/10.1108/JMTM-03-2013-0024 en_US
dc.identifier.ctation El-Khalil, R. (2015). Simulation analysis for managing and improving productivity: A case study of an automotive company. Journal of Manufacturing Technology Management, 26(1), 36-56. en_US
dc.author.email raed.elkhalil@lau.edu.lb en_US
dc.identifier.tou http://libraries.lau.edu.lb/research/laur/terms-of-use/articles.php en_US
dc.identifier.url http://www.emeraldinsight.com/doi/full/10.1108/JMTM-03-2013-0024 en_US
dc.orcid.id https://orcid.org/0000-0002-2514-1120 en_US

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