Simulation modeling based solution approach to assembly line balancing problem in a factory that produces box-type furniture

In many sectors such as furniture and machinery, enterprises are producing entirely or partially in a disassembled manner. However, especially in businesses that export to developed countries, there is a high demand for products that are fully assembled. In enterprises where production is carried out with assembly lines. This thesis study was conducted in a large-scale furniture enterprise located in Denizli, which exports all its production to developed countries. The goal was to enhance the assembly line's performance by identifying bootlenecks in the assembly line and producing solutions. The workflow, cycle time, and bottlenecks were identified by conducting work and time studies at the product's assembly station. Subsequently, five different scenarios were developed for bottlenecks and long-duration operations on the assembly line. Simulation results were evaluated statistically and a significance relationship was found. While Sanaryo-4 was determined to be the most suitable scenario according to waiting times, Scenario-2 was determined to be the most suitable scenario with a 74% product increase according to the number of products. Considering the cost, there is a machine cost in Scenario-4 and it has been determined that this cost amortizes itself in 5 years. In the other 4 scenarios, an increase in personnel in the processes is recommended. However, it has been determined that existing personnel are used and do not require extra costs. According to the statistical analysis, it was determined that the scenario that increased the efficiency of the assembly line the most was Scenario-2.