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This paper includes an approach that concentrate on optimizing the plant layout and assembly line. The simulation studies in the industries have helped through a wide range of applications. Wire harness is a set of cables grouped together leading towards little bit complexity in the assembly line at the plant. Discrete event simulation is a tool to model the complex and large manufacturing systems consisting of resources and products like robots, machines, operators, storage device, which are logically and physically linked. This study has been carried out at the small-scale electrical industry in tier-2 city Hubballi, Karnataka, India. The analysis was conducted using the simulation software and the attached results have been obtained from the simulation experiment. The bottlenecks and the loopholes were identified in the plant layout and the main aim was to improve the throughput and reduce the work in progress. These results were on the basis to propose a change in the existing plant layout and workstation station time reduction. [ABSTRACT FROM AUTHOR]

In the current scenario of competitive world, the industries are trying to make strategies at the operational level in order to increase the productivity of the plant. There is no system in the world that can go deep into the operations of the machineries and give the output as same as the real time data. When we talk about the success of any business, then, long-term planning, design, process, re-engineering, productivity etc., play a major role. The next and obvious option is the "simulation" of existing process. The simulation systems (software) can be used to perform the simulations. Each of the simulation software have their own advantages and drawbacks. The analyst or the company should understand their need for the simulation and select the software accordingly. Many experts have been upheld the need of simulations and its study in the upliftment of the existing production lines. In order to analyse the above said research problem, a motor assembly line in one of the top electrical company unit at Hubballi, Karnataka, INDIA was considered for the study. The aim of this study is to maximize the productivity of the assembly line by identifying the bottlenecks at different stages by proposing a different scenario without modifying the existing facility. [ABSTRACT FROM AUTHOR]