Simulation-Based Optimisation of ISNOO Manufacturing as a Decision Tool for Resource Efficiency

Environmental protection in sheet-metal manufacturing requires decisions that limit avoidable material consumption, waste generation and resource-intensive processing. This study presents a calibrated simulation model for resource-efficient manufacturing of an Innovative Dispatch-Receiving-Organisational System (ISNOO), a high-mix sheet-metal product. The model connects manufacturing optimisation with environmental performance through sheet nesting, overproduction avoidance, machine-state timing, buffer control and transport planning. It covers 11 production units, buffers, transport, three product variants and stochastic disturbances. A representative comparison of nesting and scheduling alternatives reduced the reported completion time from 1.33 to 1.07 days (19.5%). Shop-floor measurements were collected for a plan of 20 units per variant and an adjusted plan of 6 units per variant. Mean capability indices across eligible operation-product records were Cp = 1.142 and Cpk = 1.036 in the first campaign, and Cp = 1.615 and Cpk = 1.402 in the second. These differences reflect different production schedules and record sets; calibration improved the model representation but does not indicate improved physical process capability. The model identifies opportunities to prevent unnecessary sheet-metal processing, reduce potential scrap and rework, and convert idle-ready periods into planned shutdowns. Because direct material-loss, energy, and emission measurements were unavailable, these outcomes are proxies for resource efficiency and potential environmental benefits rather than quantified reductions in waste or greenhouse-gas emissions.