A Practical and Sustainable Approach to Industrial Engineering Discrete-Event Simulation with Free Mathematical and Programming Software

Discrete-event simulation (DES) is a powerful tool for modeling and analyzing complex systems where state changes occur at discrete points in time. This paper presents a practical and sustainable approach to implementing DES using free mathematical and programming software, making it accessible to a wider audience including educators, students, and practitioners. This study explores the use of open-source tools, such as Python and Octave, highlighting their capabilities in building and optimizing DES models without the need for expensive and unaffordable software. In the context of Industry 4.0 and smart manufacturing, the ability to simulate and optimize discrete processes with open tools contributes to the development of digital twins, the integration of cyberphysical systems, and data-driven decision-making. Through detailed case studies in industrial fields, including manufacturing, maintenance, and logistics, this study demonstrates the effectiveness of these tools in simulating real processes and promoting their sustainability. Case studies are also re-examined to emphasize their relevance to smart manufacturing, particularly in terms of predictive maintenance, process optimization, and operational flexibility. Several challenges were encountered during the research process, such as adapting DES methodologies to the limitations of general-purpose mathematical software, ensuring accurate time management and event scheduling in environments not specifically designed for simulation, and balancing model complexity with accessibility for nonexpert users. The integration of free software not only reduces costs but also promotes collaborative learning and innovation. Additionally, the paper discusses the best practices for model validation and experimentation, providing a comprehensive guide for those new to DES. By linking open-source DES tools to the objectives of Industry 4.0, we aim to reinforce the applicability of our approach to modern, connected industrial environments. By leveraging free mathematical and programming software, this approach aims to democratize the use of DES, fostering a deeper understanding and broader application of simulation techniques across diverse fields and various regions of the world.