Revolutionizing Manufacturing Layout: Enhancing Efficiency and Productivity Through Simulation and Time-Motion Analysis at Arabian Metal Industries

Abstract

Effective planning is crucial for maintaining efficiency in modern manufacturing systems, particularly in complex operations such as dump truck assembly. This study investigates the integration of simulation modeling and time-motion analysis to enhance efficiency in the assembly process of M-16 Tipper trucks at Arabian Metal Industries (AMI). The simulation revealed substantial inefficiencies, including insufficient coordination, wasteful delays, and workflow disruptions. Time-motion analysis enabled thorough oversight of activities, identifying non-value-added behaviors and sources of waste. Three simulation scenarios were developed to evaluate performance improvements. In the baseline model, only 68 of 135 trucks were completed, resulting in an efficiency of 50.4% and an average cycle time (Time in System) of 233.34 hours. In the second scenario, Opt Quest optimization improved throughput to 119 trucks (88.1% efficiency) and reduced the average cycle time to 55.69 hours, indicating a 76.1% drop. The third scenario focused on eliminating waiting periods between activities without increasing resources. This led to the manufacture of 127 trucks (94.1% efficiency) and a subsequent reduction in cycle time to 19.62 hours, indicating a 91.6% decrease from the baseline. The results demonstrate the effectiveness of combining simulation with time-motion analysis to identify bottlenecks, improve process flow, and support data-driven decision-making. This cohesive strategy improves production efficiency while promoting a more sustainable and human-centered industrial setting.