Simulation as an essential tool for advanced manufacturing technology problems

Simulation modelling has become one of the most popular techniques employed to analyse complex manufacturing systems. Within the manufacturing life cycle, simulation can be applied at both the justification phase and the design phase of manufacturing technology programmes. However, it is at the operational phase that simulation can potentially provide the greatest insights. In this paper, a simulation study is described in which the engine manufacturing facilities of a large company were modelled. The models developed were used by the company to gain valuable knowledge of the operational characteristics of their plant. The simulation results that were obtained from this study gave important insights into the behaviour of the real system and also provided invaluable knowledge to the company as to the perceived benefits of change within the current production facilities. The initial models were developed to produce an accurate emulation of the existing system, and the later models were used to experiment with different scenarios. By altering machines, shifts, labour, routing and jigs, changes were made in a series of models, so that the effects on output, work-in-progress, lead-time, machine and labour utilisation could be studied. By using simulation, to explore alternative scenarios, the best course of action was demonstrated to the manufacturer. One of the prime benefits to the company, arising from this approach is that it allowed changes to be made at the lowest cost and with the least disruption to the existing production operations.