Optimization of production processes using simulation – FlexSim

Before constructing new factories or warehouses, companies evaluate a range of internal and external factors, including production layout, storage capacity, material flow, and facility location. To aid these decisions, advanced simulation tools like FlexSim software are utilized to create digital twins—detailed digital models that replicate the structure and functioning of a facility. This study used FlexSim to analyze three variants of a production process, all with identical machine efficiency and fixed parameters. The objective was to identify the most efficient solution by examining how to maximize output, configure storage and operators to mitigate bottlenecks, and assess the workload and efficiency of process elements. The results revealed significant efficiency differences, with Variant 3 emerging as the most optimal solution, achieving the highest production efficiency. Bottlenecks in storage points were identified as the primary issue in Variants 1 and 2. The analysis also highlighted machine idle time as a factor contributing to inefficiency.