TY - JOUR
T1 - Dynamic layout optimisation through simulation: enhancing machine utilisation for fluctuating demand
AU - Mohanavelu, Thenarasu
AU - Krishnaswamy, Rameshkumar
AU - Mannepu, Venkata Roshan
AU - Seshadri, Narassima Madhavarao
AU - McDermott, Olivia
N1 - Publisher Copyright:
© The Author(s) 2025.
PY - 2025/5
Y1 - 2025/5
N2 - A change in customer demand and business priorities has shifted from mass production to mass customisation. Manufacturers can revamp and improve older manufacturing plants to increase production levels. Due to poor manufacturing facility layouts, there can be inefficient material and product flow systems. A variety of approaches may be used to aid in the design of optimal facility layouts. There is no feasible generic foundation for designing such layouts with essential data, resources, simulation and optimisation to contribute to constructing optimal facilities. In this work, a discrete event simulation (DES) model is developed for the existing assembly line for a delivery valve (DV) assembly that can meet the future demand of the assembly line for a 5-year period. Compared to the previous configuration, the new configuration improved machine usage by 40% whilst conserving 60% of space and boosting production by 75%. The study provides valuable insights into manufacturing optimisation by addressing the complexities of hybrid flow-shop assembly lines and proposing methods for optimising resource allocation and layout. This study has managerial implications in terms of making effective and efficient decisions in considering the constraints of a large solution space.
AB - A change in customer demand and business priorities has shifted from mass production to mass customisation. Manufacturers can revamp and improve older manufacturing plants to increase production levels. Due to poor manufacturing facility layouts, there can be inefficient material and product flow systems. A variety of approaches may be used to aid in the design of optimal facility layouts. There is no feasible generic foundation for designing such layouts with essential data, resources, simulation and optimisation to contribute to constructing optimal facilities. In this work, a discrete event simulation (DES) model is developed for the existing assembly line for a delivery valve (DV) assembly that can meet the future demand of the assembly line for a 5-year period. Compared to the previous configuration, the new configuration improved machine usage by 40% whilst conserving 60% of space and boosting production by 75%. The study provides valuable insights into manufacturing optimisation by addressing the complexities of hybrid flow-shop assembly lines and proposing methods for optimising resource allocation and layout. This study has managerial implications in terms of making effective and efficient decisions in considering the constraints of a large solution space.
KW - Assembly production system
KW - Discrete event simulation
KW - Facility layout
KW - Optimisation
KW - Utilisation of capacity
UR - https://doi.org/10.1007/s00170-025-15554-3
U2 - 10.1007/s00170-025-15554-3
DO - 10.1007/s00170-025-15554-3
M3 - Article
SN - 0268-3768
VL - 138
SP - 983
EP - 998
JO - International Journal of Advanced Manufacturing Technology
JF - International Journal of Advanced Manufacturing Technology
IS - 3
ER -
