Simulation in Large-Scale Precast Operations

This document details a rationalisation study on the production of shop-prefabricated parts supported by simulation to analyse potential operating alternatives, The goal was quite specific: to improve productivity and so reduce production costs. Since the study was carried out while the workshop was fully operational, no changes that would have involved stoppages in workshop production could be considered. An initial model was designed reproducing the established method, with a production rate of 75 parts per shift. The results obtained were in good agreement with the real-life situation. Alternatives were analysed . by making gradual changes to the initial model: assigning jobs to the workforce, homogenising the number of parts being processed during each of the successive stages, and altering working hours. The simulated production of the final model tested was 108 parts per shift, i.e. an increase in productivity of 44%. When this solution was implemented the model was shown to have been accurate, with the forecast production being achieved within only a few days with absolute regularity. Before the case is described, an overview of the path followed by Dragados in the process of adopting simulation as a tool for enhancing productivity is given.