A simulation-based line balancing study for a manufacturing company

Lean manufacturing is a systematic approach aimed at reducing waste within production systems while simultaneously increasing efficiency and output. Rooted in the Toyota Production System (TPS), lean manufacturing emphasizes the simplification of workflows and the continuous enhancement of processes to deliver greater value to customers with fewer resources. A fundamental principle of lean involves defining value strictly from the customer’s perspective. To support these objectives, line balancing methods are employed to optimize production flow and improve efficiency. In the studied production line, the primary issues identified include excessive motion, waiting times, and extra processing activities. Processing time data for each operation were collected through stopwatch studies and direct observations. The concept of waste reduction—central to lean manufacturing—is commonly categorized into eight types. By systematically addressing these wastes, organizations can substantially lower costs, enhance quality, and boost overall production performance. All collected data were subjected to statistical analysis using a simulation input analyser to derive expressions relevant for the current simulation model and to determine statistical significance. Furthermore, simulation software was utilized to model and evaluate the efficiency of both the existing and proposed production line configurations. The application of line balancing techniques demonstrated the potential to increase productivity by 5.4%, which in turn could reduce annual labour costs from RM180,000 to RM144,000. Ultimately, by embracing lean principles, companies can elevate customer satisfaction, strengthen competitiveness, and achieve long-term, sustainable growth.