ORGANISATIONAL ANALYSIS

Organisational Analysis

Organisational Analysis

Describing The Use Of Simulation In A Large Manufacturing Organisation and its Analyses

The benefits from using simulation were clear, it was seen that the technique could have been deployed more effectively by considering the organisational context of the use. From the analysis of the case study, certain recommendations are made on how to maximise the benefits from simulation within the organisation, thereby extending the benefits from what is often a considerable investment in developing a simulation model. Recent developments in simulation software in terms of improvements in usability and integration with organisational data are seen to increase the feasibility of a wider role for simulation if the organisational barriers discussed can be overcome.

Introduction

Simulation has been used to investigate a wide variety of problematic areas in manufacturing (Robinson? 1993). However? there is evidence that the application of simulation within the manufacturing industry has been limited owing to the fact that simulation has remained within the province of the few (Chan and Jiang? 1999). Davis and Williams (1994) report that not only is there a lack of awareness of the potential usefulness of simulation in the manufacturing sector? but among simulation developers there is also little appreciation of what manufacturing is about and what its needs are. Hollocks (1992) reports on a survey regarding the nature of simulation in the UK manufacturing industry. The findings from the report state that simulation “can virtually guarantee the design of better performing manufacturing facilities”.

It suggests that simulation can improve the education and effectiveness of a manufacturing engineer and help develop the art of decision-making. However? the report found that awareness of simulation was low with management of manufacturing organisations and? even when management was aware of it? they were unaware of the benefits of its use.

In particular? there were clear perceptions that simulation is more suited to “one-off” project work than day to day operational decision-making or any further use. Education and training at Universities? Colleges and Training centres on the uses of simulation was reported as being both limited and inconsistent. In order to provide insights into the application of simulation within UK manufacturing? there follows an examination of a case study organisation which used simulation as part of a decision-making process.

Company background

The study concerns an autonomous division of a major UK based manufacturer of railway rolling stock and equipment. The plant manufactures a range of bogies? which are the supporting frame and wheel sets for rail vehicles. The company has a history of supplying the passenger train market in the UK but over a period of time low demand and increased competition had led it to enter new markets including European inner-city transport and the supply of freight bogies to far East countries.

The production process

The facility layout is on a line basis with the manufacturing process consisting of six main stages: fabrication? welding? frame machining? paint? fitting and quality audit. Each stage must be completed sequentially before the next stage could ...