Integrated Analysis and Simulation for Enhancing Wall Assembly Process Efficiency by Resolving Bottlenecks

Unbalanced production rates of activities and abundant resource allocation are the leading reason behind bottlenecks in processes and have been one of the causes that negatively affect projects leading to wasted resources. Many industries suffer from unbalanced resource workloads, where manufacturing takt times at some workstations are out of sync with preceding stations, consequently leading to an abruption in the workflow between activities. This research aims to assess the current state of the manufacturing process of a wall assembly line from material cutting to installation, identifying bottlenecks, and creating a framework that would contrast both cycles to finally propose a solution through simulation. A case was studied to propose innovative methods to improve the process flow and to eliminate any waste generated by bottlenecks. This will not only reduce the process duration but will also significantly increase cost expenditure since the amount of idle time and resources will be reduced.