AJIBADE JOHN ADEWALE

This study aimed to evaluate and enhance the efficiency of a tile production facility in Benin City, Nigeria through MATLAB-based simulation and optimization. The research was conducted in response to persistent challenges in local tile manufacturing, including high energy consumption, low throughput, and significant defect rates. The study sought to develop a robust simulation model capable of analyzing the plant’s operational performance, identifying critical inefficiencies, and proposing optimization strategies that align with real-world production constraints. The methodology involved systematic data collection on machine utilization, downtime, energy consumption, and defect levels from the facility. These data were used to design a MATLAB simulation model that replicated the major stages of tile manufacturing mixing, pressing, drying, glazing, and firing. The model evaluated baseline performance conditions and tested multiple optimization scenarios such as load balancing, batch size adjustment, and preventive maintenance scheduling. The simulation outputs were analyzed to determine their operational feasibility within existing equipment and workforce limitations. The results showed substantial improvements across key production metrics. Daily output increased by approximately 20%, machine utilization rose from 85% to 92%, and defect rates decreased from 6.0% to 3.5%. Energy consumption per tile dropped by 7%, contributing to a 4.8% reduction in production cost. Financial projections indicated a 37% increase in monthly gross profit following optimization. These findings confirm that MATLAB simulation provides a cost-effective and practical approach for improving efficiency, product quality, and profitability in Nigeria’s tile manufacturing sector