Optimizing double glazing through time and work measurements and simulation

This study aimed to address the problem of low production rates in the double glazing process of Al Ittihad Company, which initially stood at <i>170 m</i>^<i>2</i><i>/shift (8 hours)</i>. The study employed a comprehensive methodology to identify the root causes of the issue and propose effective solutions. The methodology included interviews, data collection, time and motion study (Macro and Micro), root cause analysis, and two simulation modeling scenarios (As-Is) and (To-Be) using Arena software. Through these steps, the study revealed key issues in manual operations for small and large glass products and proposed solutions such as automation of manual pressing and insulator application activities, in addition to enhancing work standardization and employee training. The proposed solutions improvements resulted in a remarkable increase in productivity, reaching <i>212 m</i>^<i>2</i><i>/shift</i>, reflecting a <i>24.7%</i> improvement. The study also considered economic, ethical, social, and contemporary implications, emphasizing responsible and inclusive approaches. The findings and recommendations highlight the potential for continuous improvement, human-machine collaboration, and supply chain integration to further enhance the double-glazing process and drive sustainable growth in the glass manufacturing industry in Jordan.