MODELING, SIMULATION AND ANALYSIS OF AN AUTOMOTIVE MANUFACTURING SYSTEM USING ARENA SOFTWARE

The objective of this project is to develop a model, simulate and analysis a
manufacturing system using ARENA The scope of study is focusing on an automotive
manufacturer, specifically on the automotive part component stamping line. The aim is
to provide the best method to improve the workstation process efficiency and to
ascertain its limitations and problems to achieve production target. The procedures
include data gathering, model building, simulation, verification, and validation and
performance analysis. To improve understanding about ARENA, a case study is carried
out to make a simple simulation model. Then the model is simulated using the actual
stamping productions data gathered which include the production index daily, process
specification, parameters, production schedule and machine breakdown. The output of
the simulation is generated in a form of report. The report is organized into sections
which summarized across all replications. The results show that the percentage error of
ARENA model is less than 5% as targeted. This model would be used as a decision
support system for the investigation of improving the process by implementing several
decisions like line balancing and simplifYing operation. "What-if" analysis is applied to
give a review on the decision is presented. The findings confirm the qualitative
behaviour of the manufacturing system in response to the different decision options.