Simulation as a tool for the design of a textile production company

Abstract

Opportunities for improvement were identified in terms of its production methods in a uniform textile maquila, which cause large amounts of work in process and an in-continuous flow of material. For this reason, a production system was established considering lean manufacturing principles and using process simulation. The study aim was to analyze a production model for the production line and assembly of shirts in the company, through performance tests with simulations. Methods. The study had a mixed approach (quantitative and qualitative) implementing statistical tests to validate data, as well as historical data for decision making. Results. The designed production system increased daily parts production by 6% and productivity by 49%. On the other hand, the amount of work in progress was reduced in half of the stations, where lean methods were implemented. Conclusion. The proposed changes to the production system do not present an additional investment in the plant. At the same time, they generate a better daily production order, increasing it and its productivity. To be implemented in other maquilas, each one must be analyzed considering its specific situation.