Process simulation and optimization in industry 4.0: Redesigning assembly lines in an automotive industry

The experimental study conducted in an automotive company aimed to optimize the process flow and redesign service lines in the final assembly area, thereby creating physical space for the integration of new lines. Three pivotal tools were employed: the Guerchet methodology, lean manufacturing techniques, and process simulation before physical alterations. The outcomes revealed a substantial increase in production, ranging between 17% and 20%, following the implementation of the proposed changes. Furthermore, there was a reduction of 25 square meters in the physical space occupied by the final assembly service lines. This productivity enhancement signifies a significant advancement in the automotive industry, marking a milestone in service parts efficiency. In addition to the productivity impact, these changes brought about economic savings for the company. Decision-making relied on positive simulation results, allowing physical modifications solely upon their proven effectiveness in a virtual environment. This strategy not only drove productivity improvements but also positioned the company on the path towards the digitalization of its processes, as a prelude to a transition towards Industry 4.0. This strategic approach not only demonstrates enhancements in operational efficiency but also underscores the value of prior planning and the gradual adoption of digital technologies in the current manufacturing landscape. The integration of these tools offers not only immediate improvements but also a long-term vision toward a more efficient and adaptable manufacturing environment.