Simulation modeling of a facility layout in operations management classes

Teaching quantitative courses can be challenging. Similarly, layout modeling and lean production concepts can be difficult to grasp in an introductory OM (operations management) class. This article describes a simulation model developed in PROMODEL to facilitate the learning of layout modeling and lean manufacturing. Simulation allows for the evaluation of layout alternatives and the testing of labor-allocation strategies. In addition, the model shows the lead-time and resource utilization advantages of cellular layouts. Implications of these advantages for lean production are analyzed. As such, students learn to formulate operation strategies and make better decisions based on the outcomes of the simulation. Furthermore, limitations of the model and the need to generalize the model for adaptation in similar classes are discussed. Academics and others have described the difficulties of teaching quantitative models within undergraduate and graduate business programs (Hill, 2002; Johnson & Drougas, 2002). Similar difficulties, such as the anxiety of students toward the quantitative material, curriculum issues, and time constraints are observed in statistics edu-consists of a wide spectrum of quantitative and qualitative methods that enable the efficient and effective running of businesses. In most institutions, an introductory OM course is required for business majors with a diverse range of quantitative skills. Despite the mathematics and statistics prerequisites, the quantitative aspects of the course can be troublesome. Furthermore, understanding the operating system can be challenging for students who are not familiar with manufacturing or service systems. Facility layout refers to the arrangement of machines, departments, workstations, storage areas, and common areas within an existing or proposed facility (Russell & Taylor, 2003). Basic types of layouts are product, process and hybrid layouts. Layout modeling can be challenging to students. For instance, with regard to the line balancing of product layouts, Ragsdale and Brown (2004) pointed out the difficulties in formulating a model that will optimize the order of work elements and equalize the amount of work at each workstation. A spreadsheet model was developed by these researchers to facilitate the heuristics and optimization techniques required. Similar challenges are faced in the modeling process (job shop) and cellular layouts where different heuristics are developed. An effective layout design consists of eliminating bottlenecks, reducing waste, and using labor safely and in a more productive manner. In addition, facilitating the communication among workers, an easy interaction between workers and machinery, and the flexibility to adapt to changing conditions, are significant design considerations. As these require …