Lean manufacturing is functioning with maximum productivity and process efficiency, while generating quality products. Manufacturers must employ lean manufacturing to continue to be competitive. They should make use of techniques like process simulation modeling. Maintaining value with less work and effort is possible if techniques like lean design and problem solving ate employed.
It becomes possible for process simulation experts to evaluate and suggest faster ways of improvement by using of lean design. The engineers apply the technique of process simulation by making use of lean design to examine the flow of process – separately, parallelly or along with other processes and procedures for the sake of understanding the data and figuring out resolution to a problem and better practices.
When the correct source of problems with distribution techniques which directly affect Work in Process (WIP) inventory levels are indentified and resolved, that helps in reduction of those levels.
When traditional analysis was performed by using process simulation, they were able to identify the lean manufacturing blockages with absolute ease.
An automotive equipment manufacturer experienced increase in expense due to variance in their WIP process. To correct this, consultants made use of process simulation and they could easily locate bottlenecks as compared to the traditional ways of analysis, which resulted in solutions that were advantageous but would have taken very long. The solution provided removed material handling to an extent that there was an increase in worker productivity by more than 20% and gave an ROI of less than one year.