Bottleneck analysis for gear manufacturing unit by using discrete event simulation using ARENA

The identification of bottleneck process is always a big problem in many industrial processes. The issue can be addressed by understand entirely manufacturing process and optimize and utilize the resources effectively to improve productivity. This study aims to understand a gear manufacturing production line and use ARENA software to improve manufacturing efficiency. The input data for various operation cycles were collected by direct observation of the continuous manufacturing production line of the gear manufacturing plant. After conducting process flow simulation using ARENA, the bottleneck process was identified, and appropriate actions were simulated to reduce the entire process time of the gear manufacturing line. To finally arrive at workable solutions, a series of case studies are conducted to analyze the effect of simulation in each condition by utilizing "WHAT IF" scenarios.