Title: Improving the manufacturing process using Industry 4.0 tool: a simulation-based approach

Authors: Marjaneh Alsadat Seyyedrezaei; Mohsen Alvandi

Addresses: Department of Industrial Management, Faculty of Social Sciences, Imam Khomeini International University, Qazvin, Iran ' Department of Industrial Management, Faculty of Social Sciences, Imam Khomeini International University, Qazvin, Iran

Abstract: One of the pillars of the progress in the Fourth Industrial Revolution is the use of decision support tools such as simulation. Therefore, this research aims to improve the manufacturing process based on lean solutions through simulating. The authors developed several models by a discrete event simulation approach to analyse the different scenarios and used the ranking method to select the best one. The findings showed that following lean solutions can increase the average throughput by 24.88%, reduce the distance travelled by the parts up to 63% and decrease the lead time by 52%. This research is the first attempt that evaluated the effects of the concurrent use of four lean manufacturing tools on the production process improvement in an auto parts supplier company. The simultaneous use both increases the complexity of simulation models and brings the results very close to reality. So, it gives the article significant value.

Keywords: discrete event simulation; DES; process improvement; scenario analysis; decision support tools; Fourth Industrial Revolution; lean principles; AnyLogic Simulator Software; cell production; value stream mapping; VSM; multi-skilled operator.

DOI: 10.1504/IJPMB.2023.130454

International Journal of Process Management and Benchmarking, 2023 Vol.14 No.1, pp.52 - 83

Received: 16 May 2021
Accepted: 30 Jul 2021
Published online: 21 Apr 2023 *

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