Optimization Through Simulation Of Manufacturing Process using ProModel Software

Abstract

Yarmouk Industrial Complex administration (A 80 work shop- Doshka and clash manufacturing department) is facing problems in manufacturing two pieces of arms at the end of Doshka. These problems are summarize in reduced the rate of production, flow process bottlenecks, low utilization of machines, production time, production line in efficiency and production rejects . The research is focused an solve these problems through gathering the necessary information for the time of production in each station using stop watch , measuring distances between each machine and flow of production . Computer models were developed for these pieces through simulation of production line by using American computer package program ( ProModel), then corrected the models by using technicality to follow the process functioning that to make sure that the model are real in fact . After model simulation had been run to give us the expected results using in that promodel , then modifying the existing model by the suggested model in the stage of connecting the two pieces together by adding welding machine in ( A80 work shop –Doshka and clash manufacturing department ) r to make sure of the results give in this research , the results shows the following. 1- The monthly production rate increase from 85 pieces to 100 pieces. 2- Welding machine utilization increase from 59.74% to 96.47%.

v 3- Idle time for welding process reduced from 40.26% to 3.53%. 4- Eliminate bottlenecks before welding stage. 5-To release and to make ease for the employment of the machine and the stations operation efficiency after linking the two pieces increases ( welding process from 59.74% to 96.47%- heat treatment1 process from 78.57% to 99.93%- bench work1 process from 21.11% to 75.96% - grinding process 39.61% to 81.63% - drilling process from 9.61% to 88.73% bench work2 from 2.91% to 91.89% - heat treatment2 from 85.51% to 92.82%, , reducing the inventory rate to be as the benefit of yarmouk industrial complex