Process optimization through closed-loop Kaizen with discrete event simulation: A case study in China

Abstract

This article presents a closed-loop Kaizen system with discrete event simulation in the stage of design and reengineering of mass-customization production system. This approach contains four steps: current process analysis, production line design, discrete event simulation to solve the dynamic event questions, and implements and evaluation. The current process analysis and the production line design refer to the value stream mapping and the productivity analysis based on Kaizen principle, respectively. Production line designs are the modeling basis of discrete event simulation, and discrete event simulation feeds back results to the decision-makers to reduce waste and cost and improve the quality and productivity by reforming the production line. Therefore, by connecting the closed-loop Kaizen with discrete event simulation, the production line can be continuously and automatically improved. To demonstrate the potentials of the closed-loop Kaizen system, a case study was applied based on the original production layout and economic benefits were achieved. Moreover, this article indicates a direction for the full automation of process optimization.