A simulation-based modelling approach for a production line with nested-loop work sequences

Abstract

ABSTRACT Critical for current situation analysis in lean initiatives, establishing standardised work can be challenging due to the intricacies involved in documenting complex routine work, mainly characterised by nested-loop work sequences. This study aims to extend the existing methods of establishing standardised work and analysing a production line for complex routine work. Novel concepts and terminologies are introduced, combining the existing methods into a modelling approach capable of addressing all complex features simultaneously. A standardised work sequence diagram is defined as a fundamental representation, forming the basis for a new simulation-based modelling approach. Described, validated, and applied through an industrial case study, the proposed approach is confirmed effective, achieving an average relative combined cycle time of 0.99, compared to the expected value of 1. The resulting redesign of standardised work significantly improves line efficiency from 53% to 79%, with a manpower reduction from 8 to 4 workers.