Hybrid simulation modelling of the human-production process interface in lean manufacturing systems

Abstract

Purpose-This study seeks to advance a system dynamics-discrete event hybrid simulation modelling concept useful for taking improvement decisions where one needs to consider the interactions between human factors and process flow elements in lean manufacturing systems. Design/methodology/approach-A unique approach is taken to hybrid simulation modelling where the whole problem situation is first conceptualized using a causal loop diagram and a stock and flow diagram, before transmitting to a hybrid simulation model. The concept is intended to simplify the simulation modelling process and make the concept pliable for use in various types of lean manufacturing problem situations. Findings-The hybrid simulation modelling concept was applied to a lean manufacturing case where quality performance was sporadic mainly because of production pressures. The hybrid modelling concept revealed a solution that advanced full compliance with lean and one that required changes in job scheduling policies in order to promote both continuous improvement and throughput increases. Research implications-Because non-tangible aspects of lean were objectively assessed using the hybrid modelling concept, the study is an advancement towards establishing a credible link between human resource aspects of lean and the performance of an organization. Practical implications-The applied hybrid model enabled managers in the plant navigate the trade-off decision they often face when choosing to advance production output ahead of continuous improvement practices. Originality/value-System dynamics-discrete event hybrid simulation modelling is a rarity in in lean manufacturing systems.

Integration of Six Sigma and simulations in real production factory to improve performance – a case study analysis

“…Oleghe and Salonitis (2019) used a hybrid simulation model using SD and discrete-event simulation (DES) to improve a lean manufacturing process based on the human interaction with the system. The simulation model allowed the researchers to study the effect of management commitment, workforce adherence, employee perception towards lean and training on the manufacturing process.…”

A System Dynamics Model of Employees’ Performance

“…Oleghe and Salonitis [100][101][102][103][104], in a number of publications, have used system dynamics for modelling the impact of lean in manufacturing systems. They have developed models for assessing the level of leanness of manufacturing organizations [100] and the impact of implementing 5S [101] as a couple of examples.…”

“…They have developed models for assessing the level of leanness of manufacturing organizations [100] and the impact of implementing 5S [101] as a couple of examples. In a number of cases, they have used system dynamics in parallel with discrete event simulation, focusing on the former in the organizational aspects of manufacturing companies and the latter for the operations of the processes and systems in the organization [102][103][104]. In a recent study, they focused on the use system dynamics modelling approach as a strategic planning tool for analyzing business models [105].…”

Demir Çelik Endüstrisinde Torpido Taşıma Sistemi Benzetimi

“…Oleghe ve Salonitis [10] çalışmalarında, yalın üretim sistemlerinde insan faktörleri ve süreç akış elemanları arasındaki etkileşimi göz önünde bulundurması gereken iyileştirme kararları almak için bir benzetim modeli oluşturmuştur. Bu çalışma benzetim modelleme sürecini basitleştirmiştir ve model daha esnek hale getirilerek çeşitli yalın üretim problem durumlarında kullanılması sağlanmıştır.…”

“…Torpidoların taşıma kapasitelerini büyükten küçüğe doğru sıralandığında en çok 155,16 ton ile 12. torpido taşımaktadır ve en az kapasiteli torpido ise 65,08 ton ile 18. torpidodur. Büyükten küçüğe doğru sıralama 12,6,16,4,10,11,8,5,13,14 [20].…”