Enhancing performance of the loading process in a cement factory through simulation

This paper presents a discrete event simulation study of trucks and tanks loading process in the Jordan Cement Factory (JCF). The loading process is separated into two main areas; bulk and baggage depending on the state and type of cement requested. The flow of vehicles through the factory was modeled and data was collected concerning the interarrival, processing, waiting and total times of vehicles at every station for modeling and validation purposes. Two alternative systems were suggested; one alternative involves the installment of weighing scales under the loading stations so that both operations are performed simultaneously, the other alternative involves installing a second storage area for after-loading vehicle weight modifications. Using the paired t-test, a comparative study was performed between the two alternatives and the current system based on three KPIs; waiting times, total times and throughput. Results show a significant improvement in all KPIs when using either alternative over the current system. Reductions of up to 55% and 45% were observed for the average waiting and total times, respectively. Throughput was also improved by up to 8%. The study shows the power of simulation in analyzing and enhancing the performance of complex systems with minimal investment and cost.