Discrete Event Simulation (DES) and Design of Experiments (DOE) in Manufacturing Systems Development: an Application in Automotive Sector

This paper aims to present a productive capacity analysis in a manufacturing assembly line of an automotive industry. To perform this work the main tool used was Computer Simulation, using a software named ProModel, that works on Discrete Event Simulation (DES) and also using Design of Experiments (DOE), with a software named MINITAB. The first task of the project was problem definition followed by the related process mapping. This was the main element to develop the entire model. In validation process it was not used only quantitative methods, but also “hypothesis test” (1 sample-t), which is a quantitative method, using MINITAB. The study object was focused on the first shift and only for the most complex product assembled in the referred line. According to the inputs of the sub processes it was possible to identify those ones with highest potential to impact the output variable (quantity of products assembled). After processing the DOE it was possible to conclude that changes from experienced operators by new employees (operators without any experience) is the main factor to be controlled in this process in relation to productive capacity, and consequently the main cause of not reach the production plan established by manufacturing.