Productivity optimization in the electronics industry using simulation-based modeling approach

Many industrial production lines today are initially constructed and outfitted with machinery that, despite its inherent capabilities, struggles to satisfy increasing demand over time. The goal of this research is to find solutions to bottlenecks and improve the efficiency of the production line to satisfy rising productivity demands. The study primarily looks at an existing bottle production line in the edible oil industry, where the product is witnessing a boom in demand. Data on processing times at various workstations and their capacities were thoroughly collected and analyzed. Simulation emerged as the preferred tool for investigating and addressing the production line's intrinsic difficulties. Using Microsoft Excel for statistical analysis, an existing simulation model was created using Flexsim simulation, a process-oriented simulation software, to detect bottlenecks in the production line using the Processor block in the simulation. As a result, a modified model was offered to reduce waiting times by 12%, increase productivity by 6%, and increase overall profitability while efficiently dealing with rising demand across all seasons. As a result, this research represents a complete effort to identify operational challenges and present viable solutions that correspond with the industry's changing objectives. The study aims to contribute to optimizing production lines by utilizing contemporary simulation tools and statistical analysis, guaranteeing that they stay adaptive and responsive in the face of rising productivity demands.