Simulation of a Production Line in a Beverage Company in Akwa Ibom State

This study develops and applies a discrete-event simulation model to analyse the operational performance of a beverage production line in a company located in Akwa Ibom State, South South Nigeria. Simulation modelling offers a risk-free method for evaluating process changes and capacity expansion decisions, making it particularly valuable for manufacturing managers who wish to assess the impact of operational modifications before committing capital resources. The simulation model was constructed using Arena simulation software, drawing on time study data collected from the filling, capping, labelling, and case-packing stages of the production line over a six-week observation period. Input distribution fitting was performed using the software's input analyser tool to characterise inter-arrival times and service times at each workstation. The validated model was used to evaluate three scenarios: the addition of a second filling head, a reduction in changeover time at the labelling machine, and a rearrangement of the case-packing workstation. Results demonstrate that adding a second filling head yields the greatest throughput improvement, increasing line output by approximately twenty-six percent per shift. Recommendations include prioritising the filling head investment and implementing rapid changeover training for labelling machine operators. Keywords: discrete-event simulation, beverage production, Arena simulation, Akwa Ibom State, throughput