Improving Material Handling System Performance of a Toy Manufacturer Using Simulation

Abstract

This paper presents a discrete event simulation- based analysis to optimize trolley management at a leading toy manufacturer in South Asia. We address one of the many challenges faced by the toy industry, i.e., efficiently managing material handling equipment (trolleys). The paper explores an optimization approach for trolley management through the identification of critical items, clustering of sub-articles, and standardization of stacking methods. We develop simulation models to evaluate the performance of these optimized trolley management strategies. Comparison of the proposed methods with current strategies show that significant improvements can be realized in production efficiency and trolley utilization, reducing congestion and enhancing overall operational performance. The findings underscore the importance of simulation-based approaches in refining material handling processes and achieving long-term sustainability in manufacturing operations.