SIMULATION MODEL FROM

LEAN MANUFACTURING
SYSTEM
 INTRODUCTION
Lean manufacturing or lean production, is a production
practice that considers the expenditure of resources for any
goal other than the creation of value for the end customer to be
wasteful, and thus a target for elimination.
Working from the perspective of the customer who consumes a
product or service, "value" is defined as any action or process
that a customer would be willing to pay for.
 Basically, lean is centered on preserving value with less work.
As a production management tool , production theory
describes a system that deliver s a finished product free from
defects to a customer, in zero time, and with nothing left in
inventory.
 Moreover ,it can be summarized into three main points:
1. Eliminate or reduce all activities that do not add value
to the final product.
2. Pull material through the process
3. Reduce variability by controlling uncertainties within
the process.
Lean manufacturing is a management philosophy derived
mostly from the Toyota Production System (TPS) ,Taiici
Ohno, an engineer working for Toyota, developed lean
production theory.
It is renowned for its focus on reduction of the original
Toyota seven wastes to improve overall customer value,
but there are varying perspectives on how this is best
achieved.
 GOALS OF LEAN PRODUCTION
primary goal of lean production theory is to reduce or eliminate the share of
flow activities in a project while increasing the efficiency of conversion
activities.
The following list outlines key principles of lean production .
• Reduce the share of non value-adding activities.
• Increase output value through a systematic consideration of customer
requirements.
• Reduce variability.
• Reduce cycle times.
• Simplify by minimizing the number of steps, parts, or linkages.
• Increase output flexibility.
• Increase process transparency.
• Focus control on the overall process.
• Build continuous improvement into the process.
• Balance flow improvement with conversion improvement.
• Benchmark.
 METHODLOGY
The procedure starts with identifying objectives. Objectives
are then documented and studied in details.
The next step is to develop a value stream mapping to identify
material and information of the current and future states. The
number of people needed to run each cell is then determined.
The next step is to use ergonomic tools to evaluate the
proposed cells to ensure safe work environment. Simulation
modeling is then used to evaluate the performance of the
proposed manufacturing cells.
 The simulation results will be used to identify down time
factors and constraints that reduce productivity.
Possible solutions to reduce down time are then discussed and
implemented. This process is continued until desired results
are achieved.
 start

Set objective and identify

constraints

F Develop value stream mapping

L
yes
O Determine manpower required
to run the cells
W no
Ergonomic evaluation
C Accepted
H Cell evaluation using
simulation
A
R Achieved objective
yes
T implementation
Objectives
The current production system has several limitations
including ergonomic, longer material handling, lower quality,
less labor productivity, more floor space, More scrap, large
work-in-process and long setup and change over time. The
over all objective is to re-arrange the current production
system into manufacturing cells to overcome these
limitations.
1. Ergonomic
2. Quality
3. Traceability and accountability
4. Setup and change over time
Value stream mapping
The value stream mapping (VSM) one of the VMOS tools
used to identify material and information of
manufacturing processes. A VSM is usually achieved in
two states; current state and future state. The current VSM
is used as a base line to identify activities that required
achieving the future state or manufacturing cells.
• Determine the manpower
The manpower required to run each manufacturing cell is
determined at this stage. The measures used at this stage
are the balance time between the operator and the
machine, and the ergonomic constraints. The balance
time refers to the difference between the machine cycle
time and the labor cycle time requires to load and unload
all machines in the cell.
Ergonomic evaluation
At this stage, ergonomic principles are implemented to
fitting jobs to people. The Energy Expenditure and
NOISH Composite Lifting Index tools are used to
evaluate each layout and ensure safe work environment.
• Cell evaluation
The simulation technique is used at this stage to evaluate
the performance of the proposed manufacturing cells
required to run each manufacturing cell. Each
manufacturing system is simulated using Simul8
simulation software. Simul8 is a simulation software that
allows the user to create a simulation using elements that
represent machines, conveyors, buffers and parts. It is
powerful simulation software that is remarkably easy to
use and understand.
 SIMULATION MODELLING
Simulation is an extremely powerful tool that allows for a preview of
how things will run in the real word, thus allowing for a decrease in
cost, risk reduction, and preview of the possibility of failures.
 It also allows for a better understanding of the system being studied
and to perform different scenarios.
The simulation model allows possible changes to the system before
actually implemented. It also improves the utilization of technology by
determining the throughput and manpower required to run each
manufacturing cell.
Each manufacturing system is simulated using Simul8 simulation
software. Simul8 is a simulation software that allows the user to create a
simulation using elements that represent machines, conveyors, buffers
and parts. It is powerful simulation software that is remarkably easy to
use and understand.
 ASSUMPTION
The following are the assumptions used in the model:
• It is assumed that there are 8 hours per shift, 3 shifts
per day and 5 days per week.
• There are two breaks per shift and each break has 12
min.
• There is 20 min lunch per shift
• The Exponential Probability Distribution is adopted for
the Mean Time Between Failure (MTBF) and Erlang
Distribution is adopted for the Mean Time To Repair
(MTTR).
 INPUT PARAMETER
The input parameters used in the model are the machine cycle
time, MTBF and MTTR and change over and setup time.
Machine cycle time, This factor refers to the time spent by a
part at a certain operation. It includes the loading and
unloading time and machine cycle time.
Mean time between failure (MTBF), This factor refers to the
time a work center is expected to work without failing.
Mean time to repair (MTTR), This factor refers to the time
requires to fix the work-center after any failure.
Changeover and setup time, The manufacturing cell
produces several parts, which require different setup. This
factor involves the time required to changeover the cell.
 CELLULAR MANUFACTURING
Cellular Manufacturing (CM) system is an application of
lean manufacturing aims to partition manufacturing
systems into manufacturing cells .
Studies have shown that manufacturing companies that
implemented CM systems improved their productivity
level by increased output, increased rate of return on
investment, increased profit, improved quality, decreased
setup time, overdue orders and work in-process
inventories, reduced material handling cost and reduced
space requirements .
So far, very few simulation models have been developed to
evaluate the performance of cellular manufacturing
systems
 CONCLUSION
Before the model could be constructed, data was needed. This
data included the machine layout for the current
manufacturing system and proposed manufacturing cells, the
parts to be produced, the machine cycle and setup times, and
production volumes. Data is then analyzed and the model is
constructed. Both manufacturing systems are simulated and
the model .was run for 40 hours.
The results showed that the current manufacturing cell had a
productivity rate of 233 pcs/shift/man, and the proposed lean
manufacturing showed a productivity rate of 349
pcs/shift/man. That is 49% increase per operator per shift over
the traditional manufacturing system. The cellular arrangement
showed 35% decrease in labor, and 30% decrees in scrap over
the existing traditional manufacturing system.
 Simulation results

Manufacturing system Machine efficiency (%) Labor productivity Labour utilization

(Pcs/Shift/Man)
Traditional 95 233 64
Cellular 95.3 349 84.4
Thank you