AN OPTIMIZATION MODEL FOR EVALUATING PERFORMANCE RATES USING LEAN MANUFACTURING PRINCIPLES IN LEBDAH CEMENT FACTORY

Abstract

This paper discusses the application of the lean manufacturing system in Libyan industrial companies, especially in the Lebdah Cement Factory (LCF). The implementation of the lean manufacturing system (LMS) within Libyan production organizations faces many challenges such as challenges in organizing the production process and coordination between the various production processes, and the time waste due to handling operations. A simulation model has been developed for investigating the current state of implementation of lean principles, with a particular focus on the minimization of seven types of waste. FlexSim is used in the simulation process to model the production line at LCF from the arrival of raw materials to the final product. The simulation process is divided into four stages to facilitate the process. This enables tracking the production process and evaluating any delays that may occur. The results obtained from the simulation model revealed that time and resources have not been employed in an optimal manner, with a notable amount of waste occurring during the processing of raw materials. The implementation of lean manufacturing scenarios, including an optimization of conveyor lines and inventory management, resulted in a 10% increasing of the annual production and a 37% reduction in defective products