Enhancing Flexibility and Resilience of Manufacturing Systems for Small-Batch Production through Simulation Modeling

In response to increasingly dynamic production environments, small and medium-sized enterprises (SMEs) must enhance the flexibility and resilience of their manufacturing systems. Conventional evaluation methods often fail to capture the complex interdependencies and dynamic effects characteristic of small-batch production. This paper introduces a simulation-based approach utilising modular architecture and discrete-event modeling to assess flexible manufacturing systems (FMS) for potential future modifications. Prior to model development, specific criteria for simulation modeling were established, and existing research gaps were identified, ensuring efficient management of flexible process chains and adaptability across various scenarios. The independently developed model is presented as a solution, demonstrating its functions such as resource analysis of machines and other production assets, as well as the continuously evolving evaluation of personnel deployment. Case study results reveal the model’s effectiveness through alignment between simulation outcomes and actual machine runtimes, showing a 30% deviation due to workshop-based data aggregation in a toolmaking company. These findings underscore the model’s role in facilitating strategic decisions on manufacturing design. Future enhancements will incorporate additional functionalities such as disruption modeling to evaluate and bolster system resilience, further enhancing the model’s applicability in real-world scenarios.