A Simulation-Based Methodology for the Analysis of Lean Principles on Manufacturing Efficiency: An Application in Aluminum Extrusion Die Production
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Osama M. Alkhawaldeh
Aysar Alsmadi
Baha'a Altarawneh
Qais Al_Matarneh
Raneem Albtoosh
Abstract
This paper addresses the challenges and innovations in die manufacturing with regards to integrating Industrial Systems Engineering principles for optimization of processes to enhance efficiency. By combining lean manufacturing principles, Value Stream Mapping (VSM), and simulation methodologies, this research identifies and reduces inefficiencies while improving resource allocation in aluminum extrusion die production. Data collection through performance measurements and process layout analysis identifies bottlenecks and non-value-added activities, especially in flat and backer part in die production. The current layout is evaluated and improved upon by a simulation model using ARENA software in resource utilization, workflow efficiency, and waste reduction. The study further explores how Industrial Systems Engineering concepts, such as process analysis, can be applied to die design and production workflow optimization. Findings have established that lean methodologies, working in conjunction with simulation and Industrial Systems Engineering, can provide a cheaper, more effective, and sustainable die manufacturing solution.
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This work is licensed under a Creative Commons Attribution 4.0 International License.