Optimising LPG Bottling Plant With DES Using Flexsim Simulation Tool

• Published in: AFRICAN JOURNAL OF APPLIED RESEARCH Vol. 10; no. 1; pp. 547 - 556
• Main Authors: Bello, A. G., Hussin, H., Muhammad, M.
• Format: Journal Article
• Language: English
• Published: 29.09.2024
• ISSN: 2408-7920; 2408-7920
• DOI: 10.26437/ajar.v10i1.748

Purpose: This study explores the application of Discrete Event Simulation (DES) using FlexSim software to enhance the operational efficiency of a Liquefied Petroleum Gas (LPG) bottling plant. The primary goal is to ensure that the LPG plant can safely and efficiently meet escalating market demands, thereby prioritising all stakeholders' safety. Design/Methodology/Approach: The research design focused on empirical research and experimental simulation modelling. The study began with collecting and analysing one month of LPG plant data, laying the foundation for developing a simulation model. Verification and validation processes ensured the model's accuracy, enabling the investigation of various operational scenarios. The key performance indicators like First Time to Failure (FTTF), Time Between Failures (TBF), and Time to Repair (TTR) were analysed. The availability rates were 77% from actual data and 76% from simulations, showing that the model is suitable for real-world use. Findings: This study's findings underscore the potential impact of proactive maintenance strategies and operational enhancements as practical and applicable approaches to optimising performance. The analysis also revealed significant improvement opportunities through what-if scenarios: increasing MTBF by 100%, reducing MTTR by 50%, and raising conveyor speed by 15%. Research Limitation: The study's dependence on a systematic literature review could restrict its ability to capture the industry's real-time dynamics. Practical Implication: Implementing proactive maintenance strategies and operational enhancements as practical approaches can reduce downtime and costs and promote productivity and safety. Social Implication: Optimising plant operations will help maintain supply chain stability with the growing demand for LPG. Originality/Value: This work contributes valuable insights and recommendations, establishing a foundation for informed decision-making in the LPG bottling sector.