PRODUCTION LAYOUT MODEL USING WORKSTATION ANALYSIS AND SIMULATION

Production layout improvements that focused on ensuring smooth flow of operation without considering the needs of workers were deemed useless whenever operational inefficiencies occur due to worker’s health and safety. This paper developed a model that considered process variables such as cycle time and transport time, workstation variables such as body posture and awkward position, and other variables such as productivity, process efficiency and units produced to analyze and measure the performance of the framework. To test the effectiveness of the model, the proponent incorporated an actual industrial case in a garments manufacturing to evaluate existing and proposed layout results and also utilized simulation software to validate the procedure and support methodology applicability. Results indicated a 79% increase in efficiency and 186% increase in units produced as compared to existing design, and thus proved that the model is effective in improving overall operational efficiency and productivity.