Abstract
There is a tough competition in the furniture sector like other sectors. Along with the varying product range, production system should also be renewed on a regular basis and the production costs should be kept under control. In this study, spring mattress manufacturing line of a furniture manufacturing company is analyzed. The company wants to increase its production output with new investments. The objective is to find the bottlenecks in production line in order to balance the semi-finished material flow. These bottlenecks are investigated and several different scenarios are tested to improve the current manufacturing system. The problem with a main theme based on the elimination of the bottleneck is solved using Goldratt and Cox’s theory of constraints with a simulation based heuristic method. Near optimal alternatives are determined by system models built in Arena 13.5 simulation software. Results show that approximately 46 % capacity enhancements with 2 buffer stocks have increased average production by 88.8 %.
Highlights
Each company establishes its production system with the capacity to produce its product range with optimum cost
The existing production system fails to optimally respond to the product range that varies with rapidly changing fashion
Along with the modifications in the product range, the production system should be renewed on a regular basis, keeping the production costs under control
Summary
Each company establishes its production system (number of employees, machine capacities, buffer stocks) with the capacity to produce its product range with optimum cost. The aim of the current study is to improve the flow of products by reducing bottlenecks in production line using simulation tools.
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