Simulation Verification of the Design Methodology for Bottleneck Elimination in the Supply Process

This paper addresses the challenges in the supply process of a manufacturing system within an automotive company. In this production process, assembly lines are supplied using a Kanban system, and material transportation is carried out multiple times per shift by two tugger trains. To analyze bottlenecks in the process, in addition to direct observation and time studies, an RTLS (Real-Time Locating System) was utilized. This system maps, records, and provides various reports based on collected data. Using both physical observations and data from the RTLS, simulation models of the manufacturing process were developed. These digital models were then used to verify possible design proposals aimed at improving efficiency and optimizing production pro-cesses within the company. The proposed solution for the selected production process effectively eliminates bottlenecks in material transportation for final product manufacturing. A methodo-logical approach for data collection and the simulation of the supply process for production lines is also presented. The paper concludes with a methodology for the continuous improvement of the supply process through system integration and outlines future research directions in this field.