Factory Throughput Simulation

Engineering Context

Nova Factory Systems is considering three production-line configurations. Building each physically would be costly, so your team must simulate the alternatives and recommend the best design for throughput and reliability.

What You Will Practice

• Build and compare production scenarios
• Identify bottlenecks and buffer effects
• Analyze throughput and utilization data
• Complete an evidence-based trade study

What You Need

• Digital twin or factory simulation
• Three provided layout scenarios
• Spreadsheet
• Engineering notebook

Instructions

1. Define the production sequence and output target.
2. Build or load Scenario A with the baseline robot and conveyor settings.
3. Run a simulated production period and record output, idle time, and blocked time.
4. Create Scenario B by changing conveyor speed or buffer capacity.
5. Create Scenario C by changing robot path or station assignment.
6. Run each scenario for the same simulated duration.
7. Calculate throughput, robot utilization, and average work-in-process.
8. Create a weighted decision matrix using output, reliability, complexity, and cost.
9. Recommend one scenario and identify one risk before physical implementation.

Engineering Requirements

• Compare exactly three scenarios
• Use identical simulated production duration
• Report throughput and at least two additional metrics
• Support recommendation with a decision matrix

Constraints & Safety

• Use only approved changes for each scenario
• Do not change multiple unrecorded variables
• Simulation assumptions must be listed
• The recommended scenario must preserve safety

What You Submit

• Three simulation configurations
• Scenario data table
• Graphs of key metrics
• Decision matrix
• Recommendation memo
• Reflection

Reflection Questions

1. Which scenario had the highest throughput?
2. Did highest throughput also produce the least work-in-process?
3. What assumption could change the recommendation?
4. Which result should be verified physically first?