Simulation-based Optimisation of Manufacturing Systems Using Lean Techniques

Abstract

This thesis studied the ACME stamping manufacturing firm, a hypothetical but still realistic production line. through simulation to compare push and pull production control systems and evaluate how they handle increased product variety. Four simulation models were created in Siemens Tecnomatix Plant Simulation based on current-state and future-state value stream maps. The push-based production line struggled to meet customer demand and became less efficient when product variety increased because of bottlenecks and higher changeover times. In contrast, the pull-based production line maintained stable performance and continued meeting demand through the use of kanban systems, supermarkets, and reduced changeovers. The results showed that pull production control combined with value stream mapping and discrete event simulation is a more effective approach for improving manufacturing performance and handling changing market demands.