Simulation-Based Decision Support System to Improve Material Flow of a Textile Company

Vítor Silva,Francisco J G Silva,Luís Pinto Ferreira,Benny Tjahjono,Paulo Ávila

doi:10.3390/su13052947

Abstract

To remain competitive, companies must continuously improve the processes at hand, be they administrative, production, or logistics. The objective of the study described in this paper was to develop a decision-making tool based on a simulation model to support the production of knits and damask fabrics. The tool was used to test different control strategies for material flow, from the raw material warehouse to the finished product warehouse, and thus can also be used to evaluate the impacts of these strategies on the productivity. The data upon which the decision support tool was built were collected from five sectors of the plant: the raw material warehouse, knit production, damask production, finishing work, and the finished product warehouse. The decision support tool met the objectives of the project, with all five strategies developed showing positive results. Knit and damask production rates increased by up to 8% and 44%, respectively, and a reduction of 75% was observed in the waiting time on the point of entry to the finishing work area, compared to the company’s existing system.

Highlights

Continuous improvement has emerged as an essential strategy in enhancing competitiveness in a world where excellence prevails
Shop floor efficiency can be improved by addressing operational issues to achieve fast or smooth flow of raw materials, work-in-progress, and information within a production network
Working within the production planning department, the study described in this paper aimed to evaluate different control strategies for material flows from the raw material

Summary

Introduction

Continuous improvement has emerged as an essential strategy in enhancing competitiveness in a world where excellence prevails. Shop floor efficiency can be improved by addressing operational issues to achieve fast or smooth flow of raw materials, work-in-progress, and information within a production network. The company is constantly under pressure to provide products and solutions that are increasingly demanding in terms of new design, high quality, and quick delivery. For this reason, the company has dedicated lines of fibers and innovative finishes in the manufacture of apricots and knits intended for mattress covers, but it does require robust control strategies for the material flows

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Conclusion