Simulation software is becoming an increasingly important tool for manufacturing industries. This is a case project from Autoliv company, and the work was carried out at Autoliv in Thailand, they are producing different products for automotive applications such as Airbags, seat belts, Steering wheels, and Buckles. Currently, Autoliv in Thailand uses a lean production flow approach (i.e, Industry 3.0) and aims to implement a new side airbags Assembly line in the future (to have more automation in production).

For this project, two cases were presented.

Case1: Autoliv in Thailand already used the traditional line balancing method for their pre-existed SAB assembly line, and they successfully achieved the customer demand in the existing SAB assembly line. In this thesis work, this same case has been analyzed with the DES method, and the results of the simulation solution are compared with the real environment output.

Case2: This case analyses the assembly flow of the upcoming new SAB assembly line with the help of plant simulation software. The Purpose of doing this analysis is to predict the throughput efficiency and make improvements to the assembly line before implementing it into the real environment. For this, a simulation model was created with different manpower scenarios and analyzed. In that, the best solution was presented in this thesis.

With all the collected data, the simulation model is presented and analyzed for three assembly lines. The software used for this project is Siemens’s Tecnomatix Plant Simulation. By using this simulation method, In the first case, the simulation results achieved 90-95% same as the real environment output and prove a simulation method is a good tool for balancing the assembly line. In the second case, throughput has been predicted and made improvements to the upcoming new assembly line by reducing the number of workers from 5 to 3 in the simulated environment.