Simulation-Driven Production Layout Optimization: A Case Study in Heavy Machinery Manufacturing

Production layout optimization is essential for increasing production efficiency, lowering material handling time, and increasing total output. However, industries frequently meet challenges such as inflexible transportation infrastructure, inefficient material movement, and logistical complications, which impede operational effectiveness. To solve these difficulties, simulation-based approaches have emerged as useful tools, allowing industry to virtually test alternative designs and operational strategies prior to adopting actual changes. This study presents a case study from a heavy machinery manufacturing company, in which a current state simulation model was developed in order to investigate improvements within a production cell. Thereafter, multiple scenarios have been developed in 3D visual simulation software to evaluate variations in transport techniques, material flow configurations, washing station placements, and fixture dependencies. The purpose was to assess the impact of these factors on production output and operational flexibility. The simulation results revealed that configurations emphasizing flexible transport and streamlined internal logistics achieved the highest production efficiency. Overall, the findings suggest that carefully redesigning internal material flows and minimizing reliance on rigid systems can substantially enhance manufacturing performance. Therefore, for this study, simulation-driven approach proved to be a valuable tool for identifying practical improvements without disrupting the ongoing operations.