Flexible production is able to respond to a changing production system. To efficiently optimize a changed production layout and configuration, a modelling and optimization method based on discrete event simulation (DES) was proposed. A mathematical optimization model of the workshop layout was formulated and solved using a genetic algorithm (GA). In addition, a general modelling method for workshop logistics processes using DES was proposed to efficiently develop a simulation model of the complex production processes. Moreover, the simulation model of the entire production process was constructed using the Plant Simulation software package, and more production factors were considered and optimized. After the optimization process, the logistics volume decreased by 63.5 %, and the throughput increased by 42.0 %. Additionally, the production process was optimized, and the optimal equipment allocation, worker allocation, buffer allocation, and logistics vehicle allocation were determined. Our work can provide decision guidance and simulation validation for workshop planning.

Aiming at the gap between theoretical research and practical application in the production bottleneck field, we apply five bottleneck identification methods in a serial production line in aerospace industry based on discrete event simulation and Plant Simulation software, meanwhile discuss the influence of the bottleneck machine quantity on the system performance. This paper evaluated the practicability, accuracy and limitation of various bottleneck identification methods at the practical level. The results of the bottleneck alleviation manifest that increasing the number of bottleneck machines can effectively improve the system performance, but the more machine quantity, the smaller performance improvement. More importantly, the paper studies the influence mechanism and function relationship of the bottleneck machine quantity on the maximum completion time from an interesting actual phenomenon for the first time. The function obtains the condition that the maximum completion time achieves the minimum. The research and conclusion of this paper have essential reference significance for production guidance and theoretical research, and can also contribute to narrow the gap between theory and application of the production bottleneck field.