Simulation-Based Optimization of Material Supply in Automotive Production Using RTLS Data
Source abstract
Abstract
This study presents a comprehensive simulation-driven approach to identify and mitigate bottlenecks in the supply flows of an automotive manufacturing system. The supply process relies on a Kanban-based assembly line replenishment, supported by multiple material transports per shift using tugger trains. To analyze flow constraints, the research combines time–motion studies with data from a Real-Time Locating System (RTLS), enabling spatial-temporal mapping of material movements. Based on this data, digital-twin simulation models of the supply process were developed and validated. These models allowed testing of improvements aimed at increasing throughput and efficiency. The proposed methodology demonstrates effective bottleneck resolution and provides a structured framework for data collection and simulation integration. Unlike traditional observation-based approaches, the use of RTLS enables precise detection of routing deviations and operator behaviors. The simulation model was tested under real operating conditions and validated against ground-truth data. Results showed a reduction in collisions and delivery delays, as well as measurable productivity and financial gains. This approach offers a practical and transferable method for optimizing intralogistics in modern production environments.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Flexible and Reconfigurable Manufacturing Systems · Manufacturing Process and Optimization · Scheduling and Optimization Algorithms
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Faculty of Mechanical Engineering, Department of Industrial and Digital Engineering, Technical University of Košice, Park Komenského 9, 042 00 Košice, Slovakia
Faculty of Mechanical Engineering, Department of Applied Mathematics and Informatics, Technical University of Košice, Letná 9, 042 00 Košice, Slovakia
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