Application Of Discrete-Event Simulation For Bottleneck Problems In Footwear Manufacturing: A Case Study Of Tbs Group Skechers Factory

Abstract

Thai Binh Shoes Group is dealing with the problem of bottlenecks in their Skechers footwear manufacturing line due to overcrowding of materials in the machining sections. This has caused the overall system throughput to slow down since the later stations have to wait until one piece of each type of material is ready for assembling. In order to settle the problem, discrete event simulation (DES) was used to simulate the flow of the actual production line in one section of TBS’s factory, to provide the researcher with deeper insights into the material flow, the resource and workforce distribution status, from which the bottlenecks were found. The data used as inputs for the simulation model was collected from TBS Group Thuan An Skechers factory, both through direct observation and provided by the Production Manager. Then, adjustment options were proposed through the changes in human resource allocation and batching schemes to reach the goal of improving and rebalancing the system’s resource utilization. Statistical comparison methods such as independent sampling and common random numbers were used and the scenario with the most optimal result was chosen. Although this may not be the universal solution to every single bottleneck problem in the entirety of TBS’s factories as well as the footwear industry as a whole, but it can contribute as a reference as for how simulation can be applied in this industry, thus aiding in future research and studies for more thorough improvements.