Analysing the Bottleneck in Crankcase Cover Manufacturing using Simulation and Modelling

Before constructing the actual production plant architecture, the simulation builds a virtual production model that is identical to the real environment and offers insights into the future. By using simulation, we can test the behaviour of the expensive and sophisticated manufacturing system without physically putting any money in it. In this study, Flexsim is used for the first time to model and simulate the production of two-wheeler crankcase covers. In this work, a simulation model for crankcase cover production processes in the automotive sector is developed. Flexsim simulation tool is used as an optimization tool for analysing the bottleneck or performing the line balancing. The results indicate that by eliminating the bottleneck in the production line, it increases the line efficiency as well as the production throughput. Initially production line efficiency is just 51.8% when bottleneck is present. After bottleneck is removed, it increases not only throughput but also line efficiency to 97.29%. All manufacturing sectors will profit from these findings.