Optimization on the shop floor - A business simulation Approach

Assembly processes can be optimized with various methods. However, it is difficult to evaluate the effectiveness and interaction of these methods. To date, shop floor improvement methods in series production, such as the methods under investigation 5S, Poka Yoke, Kanban, and Standard Work Sheet, have not been scientifically analyzed using a business simulation. This study is aimed at closing this research gap by conducting a business simulation and analyzing the generated data using the design of experiments. This combination represents a new form of research. For the design of experiments, full factorial design with four factors was used. Lead time is selected as the KPI. By analyzing the lean methods that were investigated in this study, both main effects and interactions were found. Results show that it is useful to apply at least one optimization method, whereby Poka Yoke has the most significant impact on the lead time. Researchers in the field of optimization methods can base their investigations on this study.