<b>Evaluation of Cement Production for Continuous and Discrete Flow Systems by Applying a Discrete Event Simulation Approach</b>
Wan Laailatul Hanim Mat Desa, Mohd Kamal Nawawi, Nur Anis Hannan Md Shahid
Source abstract
The purpose of this study is to model and simulate the operations of the cement manufacturing industry using the Discrete Event Simulation (DES) approach. The study focuses on improving operational efficiency and supporting decision-making through systematic process analysis and modelling. Although cement manufacturing consists of three main stages, including raw material preparation, pyro processing, and cement grinding and distribution, this study adopts a tank-flow approach to analyze material flow behavior during the critical cement grinding process. A simulation model was developed using Arena Software version 16.2 to represent both continuous and discrete flow characteristics of the system. Four alternative scenarios were evaluated against the basic model. According to the results, Scenario 2 reduced the mixing time of Mixing Tank 2 by almost 22%, while Scenario 3 obtained the lowest average total mixing time for Mixing Tank 1 (2.194 hours), which is a decrease of roughly 32% when compared to the basic model. Scenario 4 significantly increased the accumulation in Mixing Tank 2 (4046.9 tons) in terms of tank levels, suggesting possible bottlenecks downstream. These results emphasize the difference between higher inventory levels and shorter processing times. Preventive maintenance techniques are suggested, considering the simulation results, in order to reduce delays and manage excessive material accumulation, which will enhance system dependability and overall operating performance.
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