Optimizing Sugar Manufacturing: A Hybrid Simulation-Based Approach and MCDM for Efficient Decision Making

Efficient truck flow is essential for the efficient operation of a factory and the distribution of its products. This study demonstrated methods to improve truck loading times and overall efficiency at a major sugar manufacturing facility in the Middle East. The objective was to reduce truck waiting times at loading units and increase capacity. The data were collected through questionnaires, observations, and interviews with stakeholders. A simulation software was employed to analyze truck activity at loading stations at the factory. Multi-criteria decision making (MCDM) tools, AHP and TOPSIS, addressed five primary criteria and nine sub-criteria to assist in identifying, evaluating, and ranking feasible solutions. The study suggested different utilization of the various factory loading platforms at different times of the day. The findings from this study emphasize the importance of simulation-based approaches supplemented with decision-making processes to improve efficiency in sugar manufacturing facilities that may have broader applications in the factories of other industries. The study highlights remarkable improvements in operational efficiency, as seen in Alternative 4 substantial 27.9% enhancement, resulting in cost savings and time efficiency. By implementing these findings, factories can enhance their truck flow management system, reduce waiting times, increase capacity utilization, optimize resource allocation, and improve overall efficiency.