IDEAS home Printed from https://ideas.repec.org/a/gam/jsusta/v15y2023i3p2331-d1048402.html
   My bibliography  Save this article

The Evaluation and Improvement of the Production Processes of an Automotive Industry Company via Simulation and Optimization

Author

Listed:
  • Durdu Hakan Utku

    (The Department of Industrial Engineering, University of Turkish Aeronautical Association, Etimesgut, Ankara 06790, Turkey)

Abstract

Production delays are significant problems for the loss of goodwill of the customers and the loss of profits associated with them. The delays may accrue as a result of insufficient resource planning and poorly designed unsatisfactory procedures. In this study, a new mathematical model is proposed to optimize the production processes by minimizing production delays, and a simulation model is developed to test the alternative facility designs. The purpose is to increase customer satisfaction by ensuring that the products are delivered timely and preventing lost sales in an automotive company that manufactures garbage collectors by using real data. The mixed-integer programming problem related to the minimization of production delays is solved by the GAMS CPLEX 24.1.3 software. In this way, the total delay in the production area is minimized by the mathematical model to prevent labor and time loss. Accordingly, the alternative designs are investigated for the improvement of the production processes by using discrete system simulation. A system analysis is performed to determine the bottlenecks in the production processes by developing a simulation model via the ARENA simulation software. With the proposed facility layout alternatives, the delays are eliminated, the total production time is reduced, and an increase in production efficiency is observed.

Suggested Citation

  • Durdu Hakan Utku, 2023. "The Evaluation and Improvement of the Production Processes of an Automotive Industry Company via Simulation and Optimization," Sustainability, MDPI, vol. 15(3), pages 1-17, January.
    • Handle: RePEc:gam:jsusta:v:15:y:2023:i:3:p:2331-:d:1048402
    as

    Download full text from publisher

    File URL: https://www.mdpi.com/2071-1050/15/3/2331/pdf
    Download Restriction: no
    File URL: https://www.mdpi.com/2071-1050/15/3/2331/
    Download Restriction: no
    ---><---

    References listed on IDEAS

    as
    1. Liu, Xuejuan & Wang, Wenbin & Peng, Rui, 2015. "An integrated production, inventory and preventive maintenance model for a multi-product production system," Reliability Engineering and System Safety, Elsevier, vol. 137(C), pages 76-86.
    2. Cavagnini, Rossana & Hewitt, Mike & Maggioni, Francesca, 2020. "Workforce production planning under uncertain learning rates," International Journal of Production Economics, Elsevier, vol. 225(C).
    3. Tarik Aouam & Kobe Geryl & Kunal Kumar & Nadjib Brahimi, 2018. "Production planning with order acceptance and demand uncertainty," Post-Print hal-01998733, HAL.
    4. Yun, Huimin & Wang, Meng & Feng, Wei & Tan, Tianwei, 2013. "Process simulation and energy optimization of the enzyme-catalyzed biodiesel production," Energy, Elsevier, vol. 54(C), pages 84-96.
    5. Matthias Thürer & Nuno O. Fernandes & Mark Stevenson, 2022. "Production planning and control in multi-stage assembly systems: an assessment of Kanban, MRP, OPT (DBR) and DDMRP by simulation," International Journal of Production Research, Taylor & Francis Journals, vol. 60(3), pages 1036-1050, February.
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Zhao, Xian & He, Zongda & Wu, Yaguang & Qiu, Qingan, 2022. "Joint optimization of condition-based performance control and maintenance policies for mission-critical systems," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    2. Kajjoune, Oussama & Aouam, Tarik & Zouadi, Tarik & Ranjan, Ravi Prakash, 2023. "Dynamic lot-sizing in a two-stage supply chain with liquidity constraints and financing options," International Journal of Production Economics, Elsevier, vol. 258(C).
    3. Gössinger, Ralf & Helmke, Hanna & Kaluzny, Michael, 2017. "Condition-based release of maintenance jobs in a decentralised production-maintenance system – An analysis of alternative stochastic approaches," International Journal of Production Economics, Elsevier, vol. 193(C), pages 528-537.
    4. Manda, A.B. & Uzsoy, Reha, 2021. "Managing product transitions with learning and congestion effects," International Journal of Production Economics, Elsevier, vol. 239(C).
    5. Carlos Cuartas & Jose Aguilar, 2023. "Hybrid algorithm based on reinforcement learning for smart inventory management," Journal of Intelligent Manufacturing, Springer, vol. 34(1), pages 123-149, January.
    6. Jaber, M.Y. & Peltokorpi, J. & Glock, C.H. & Grosse, E.H. & Pusic, M., 2021. "Adjustment for cognitive interference enhances the predictability of the power learning curve," International Journal of Production Economics, Elsevier, vol. 234(C).
    7. Junzo Watada & Nureize Binti Arbaiy & Qiuhong Chen, 2021. "Hybrid Uncertainty-Goal Programming Model with Scaled Index for Production Planning Assessment," FinTech, MDPI, vol. 1(1), pages 1-24, November.
    8. Yang, Li & Zhao, Yu & Peng, Rui & Ma, Xiaobing, 2018. "Hybrid preventive maintenance of competing failures under random environment," Reliability Engineering and System Safety, Elsevier, vol. 174(C), pages 130-140.
    9. Biswajit Sarkar & Bikash Koli Dey & Mitali Sarkar & Ali AlArjani, 2021. "A Sustainable Online-to-Offline (O2O) Retailing Strategy for a Supply Chain Management under Controllable Lead Time and Variable Demand," Sustainability, MDPI, vol. 13(4), pages 1-26, February.
    10. Polotski, V. & Kenne, J.-P. & Gharbi, A., 2019. "Joint production and maintenance optimization in flexible hybrid Manufacturing–Remanufacturing systems under age-dependent deterioration," International Journal of Production Economics, Elsevier, vol. 216(C), pages 239-254.
    11. Vadery, Vinu & Narayanan, Binitha N. & Ramakrishnan, Resmi M. & Cherikkallinmel, Sudha Kochiyil & Sugunan, Sankaran & Narayanan, Divya P. & Sasidharan, Sreenikesh, 2014. "Room temperature production of jatropha biodiesel over coconut husk ash," Energy, Elsevier, vol. 70(C), pages 588-594.
    12. Tsionas, Mike G., 2023. "Bayesian learning in performance. Is there any?," European Journal of Operational Research, Elsevier, vol. 311(1), pages 263-282.
    13. Vávra, Aleš & Hájek, Martin & Skopal, Frantisek, 2017. "The removal of free fatty acids from methyl ester," Renewable Energy, Elsevier, vol. 103(C), pages 695-700.
    14. Pourzolfaghar, Hamed & Abnisa, Faisal & Daud, Wan Mohd Ashri Wan & Aroua, Mohamed Kheireddine, 2016. "A review of the enzymatic hydroesterification process for biodiesel production," Renewable and Sustainable Energy Reviews, Elsevier, vol. 61(C), pages 245-257.
    15. Janbarari, Seyed Reza & Ahmadian Behrooz, Hesam, 2020. "Optimal and robust synthesis of the biodiesel production process using waste cooking oil from different feedstocks," Energy, Elsevier, vol. 198(C).
    16. Kumar, Ashok & Gudiukaite, Renata & Gricajeva, Alisa & Sadauskas, Mikas & Malunavicius, Vilius & Kamyab, Hesam & Sharma, Swati & Sharma, Tanvi & Pant, Deepak, 2020. "Microbial lipolytic enzymes – promising energy-efficient biocatalysts in bioremediation," Energy, Elsevier, vol. 192(C).
    17. Liang, Xuezheng, 2013. "Synthesis of biodiesel from waste oil under mild conditions using novel acidic ionic liquid immobilization on poly divinylbenzene," Energy, Elsevier, vol. 63(C), pages 103-108.
    18. Ba, Kader & Dellagi, Sofiene & Rezg, Nidhal & Erray, Walid, 2016. "Joint optimization of preventive maintenance and spare parts inventory for an optimal production plan with consideration of CO2 emission," Reliability Engineering and System Safety, Elsevier, vol. 149(C), pages 172-186.
    19. Yang, Li & Ye, Zhi-sheng & Lee, Chi-Guhn & Yang, Su-fen & Peng, Rui, 2019. "A two-phase preventive maintenance policy considering imperfect repair and postponed replacement," European Journal of Operational Research, Elsevier, vol. 274(3), pages 966-977.
    20. Pereira, Daniel Filipe & Oliveira, José Fernando & Carravilla, Maria Antónia, 2020. "Tactical sales and operations planning: A holistic framework and a literature review of decision-making models," International Journal of Production Economics, Elsevier, vol. 228(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:gam:jsusta:v:15:y:2023:i:3:p:2331-:d:1048402. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: MDPI Indexing Manager (email available below). General contact details of provider: https://www.mdpi.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.