A Comparison of the Effects of Worker-Related Variables on Process Efficiency in a Manufacturing System Simulation

Purpose: The goal of this study was to build an accurate digital factory that evaluates the performance of a factory using computer simulation. To achieve this goal, we evaluated the effect of worker-related variables on production in a simulation model using comparative analysis of two cases. Methods: The overall work process and worker-related variables were determined and used to build a simulation model. Siemens PLM Software's Plant Simulation was used to build a simulation model. Also, two simulation models were built, where the only difference was the use of the worker-related variable, and the total daily production analyzed and compared in terms of the in dividual process. Additionally, worker efficiency was evaluated based on worker analysis. Results: When the daily production of the two models were compared, a 0.16% error rate was observed for the model where the worker-related variables were applied and error rate was approximately 5.35% for the model where the worker-related variables were not applied. In addition, the production in the individual processes showed lower error rate in the model that included the worker-related variables than the model where the worker-related variables were not used. Also, among the total of 22 workers, only three workers satisfied the IFRS (International Financial Reporting Standards) suggested worker capacity rate (90%). Conclusions: In the daily total production and individual process production, the model that included the worker-related variables produced results that were closer to the real production values. This result indicates the importance of work er elements as input variables, in regards to building accurate simulation models. Also, as suggested in this study, the model that included the worker-related variables can be utilized to analyze in more detail actual production. The results from this study are expected to be utilized to improve the work process and worker efficiency.