Quantifying benefits of conversion to lean manufacturing with discrete event simulation: A case study

Simulation is used to assist in the decision to implement lean manufacturing principles at an existing assembly operation. Models are developed for the existing assembly system, as well as for a new system (of similar capacity), that employ these principles. In addition to the manufacturing processes, the associated warehousing, inventory management, transportation, and production control/scheduling systems are included in the model to enable the quantification of lean manufacturing's impact on the total system. Simulation experiments measure each system's resource requirements and performance, thereby quantifying benefits to be derived from applying the shop-floor principles of lean manufacturing.