A roadmap to improving productivity in a fastener manufacturing unit by process optimization using ARENA

Abstract

In an increasingly competitive market, the need for resource maximization is ever-present. Efficient and maximum optimization is desired throughout the organization. This paper focuses on methods and techniques that can achieve said effectivity in production through mainly heuristic means. Hence these techniques are ideal for engineers in management. They are based on both experience of personnel and scientific analysis of academicians, thus creating an excellent and executable plan that is straightforward, flexible and practical. A detailed study and analysis of the manufacturing unit was carried out. Personal interactions with the operators and employees in their workplace, during work hours, greatly helped in problem identification. Each problem was identified was then categorized and observed to gather solutions for improvement in quality and productivity of the process from which the problem originated. An intensive time-study analysis was also done to understand the inefficiencies in process flow and the results were simulate on Arena Simulation Software and various models for improved models were proposed. These improved models were found by either adjusting resources or eliminating processes, thus improving output. Thus, this research will be beneficial for practitioners and researchers alike, for tacking various inefficiencies in an organization.