Simulation Modelling as a Tool for Automotive Wiring Assembly Optimisation: Application in Real Case Studies

• M. Adel Department of Mechanical Design and Production Engineering, Assiut University, Assiut, Egyp https://orcid.org/0009-0004-0636-6414
• R.M. El-Zahry Department of Mechanical Design and Production Engineering, Assiut University, Assiut, Egypt https://orcid.org/0009-0001-0405-2903
• M. Heshmat Department of Mechanical Design and Production Engineering, Assiut University, Assiut, Egypt | 2 Ningbo China Institute for Supply Chain Innovation, MIT Global SCALE Network, Ningbo, China https://orcid.org/0000-0003-1492-4223

DOI:

https://doi.org/10.7166/36-4-3230

Abstract

Discrete-event simulation is a valuable tool for optimising production plants. The present study explores an automotive power cable wiring assembly line’s process through four real case studies, modelled using actual production data and simulated in ARENA software. Statistical analysis using PRISM identified bottlenecks, waiting times, and work-in-progress, offering key insights for improvement. The models are adaptable to other assembly lines, with potential advancements in scheduling and machine learning. By combining simulation modelling and statistical validation, the study provides practical recommendations to enhance efficiency, reduce waste, and improve performance in automotive manufacturing.