Simulation Modeling and Analysis of a Door Industry

Ιn this paper, the authors study the production line of a door industry. The first stage of this research consists of the detailed documentation with flow charts and systematization of all production processes, all product types, as well as all stages of production and equipment. The standard production times were calculated for each workstation, together with the relevant workforce requirements. In the second stage of this research, a discrete event simulation model of the factory was developed to assist in the production planning decision-making. The simulation model was verified using actual production data relating to 19 customer orders for a total of 1,281 doors. Four simulation experiments were executed, where the effect of alternative shifts on the manufacturing line's efficiency was investigated. The performance metrics of total production, mean daily production, and mean labor cost per product were considered. This experimental trial resulted in the identification of the shift configuration that achieves increased productivity while maintaining relatively low labor costs.