Production Process Simulation-Lean Manufacturing Simulation

????????Production process Simulation-Lean Manufacturing Simulation

? In FMCG plants, especially Biscuits Manufacturing units the production time place a vital role in the performance of the factory.

Indian Biscuit Industry has seen a major trend and started gaining good growth in bakery, food industry. The growing demand in this industry has seen a sharp curve in late 20’s. Today the total production is estimated to be around 30 lakh metric tonnes. While the biscuit industry is estimated to grow around 15-17% in the next few years. The biscuit per capita consumption in India is 2.0kg.

The Industry is struggling to meet this demand especially when the cost of production is going high. we need to find a balance and optimal resource utilisation methodology in other words we need to bring Lean manufacturing concepts established to address the problems. It is important the process of biscuit production to apply lean manufacturing principles.

The following picture depicts the general process followed for Biscuit Manufacturing

Discrete Event simulation to estimate Production per day:

?Normally Small-scale industries produce 400 to 450 kgs of biscuits per day.

Large scale industries produce nearly 1.5 to 2 tonnes per day

In order to increase production to meet the demand levels, there is a need of increasing the number of production lines, which results in higher capital investment and also an onerous task.

Key Resultant Areas :

1.??????Determine optimal process time.

??????To configure process time for Batter filling and Cream filling machines.

2.??????Evaluate sorting machine Performance vs Demand.

????????To analyse the utilization of sorting machines as per production demand

3.??????Calculate output for every machine.

????????To calculate the ratio of Number of Cardboard boxes packed by each packing machine.

4.??????Determine output per day.?????????????????????????????????????????????????????????

?????????To quantify the production per day.

?

Production per day??????????????--- 12, 67,200 biscuits.??????

Production per month????????--- 38,016,000 biscuits.

Production per year????????????--- 456,192,000 biscuits.