Analysis of a Modular Housing Production System Using Simulation

This paper presents the development of a simulation model for an existing modular housing factory. The activities of the system under study were mapped out, and the process time and total cycle time data of approximately 20 cycles were collected for all activities at the assembly and subassembly stations. Modeling assumptions were determined based on the real system constraints that were observed during the data collection process. The observed constraints included types and sizes of housing units produced and the ways these various types were processed through the system. The model was verified by observing the animation of the entities at a low speed run after each development committed on the model to check that entities are directed through the correct logic. The model was validated by comparing the production output of the model performance measures with the real system outputs. The run results showed a bottleneck free system with average queue time at stations one to station three of 60, 5, and 3.6 minutes respectively over a one week of operation, which is considered to be insignificant. The simulation model provides an efficient tool for production managers to evaluate and analyze the MH production system i) decide the appropriate product mix batch sizes and ii) locate potential bottlenecks hindering the productivity. (C) 2010 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved