EVALUATION OF PERFORMANCE IMPROVEMENT USING MATLAB SIMULATION IN A TILE PRODUCTION FACILITY
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Abstract
The ceramic tile manufacturing industry is vital to the construction sector, providing durable and aesthetic materials for diverse applications. In Nigeria, however, many tile production facilities face persistent challenges such as inefficiency, high production costs, and inconsistent quality due to outdated equipment and limited process control. Previous studies have shown that
simulation-based optimization, particularly with MATLAB, offers significant potential for improving manufacturing efficiency, but its application in local tile production remains limited. This study addresses this gap by exploring how MATLAB-based simulation can be employed to evaluate and enhance the performance of a tile production facility in Benin City, Edo State. The methodology involved collecting comprehensive production, machine, material, energy, and quality control data from a selected facility. These datasets were organized and converted into MATLAB struct format, enabling the development of a simulation model that replicated key stages of the production process. The model was used to run a five-year performance analysis, incorporating variables such as machine utilization, defect rates, energy consumption, and production output. Incremental optimization strategies such as adjusting batch sizes, refining firing schedules, and improving maintenance planning were introduced to assess their potential
impact on operational efficiency and cost reduction. Results from the simulation revealed gradual but consistent performance improvements over the five-year period, including increased daily output, higher machine utilization, reduced defect rates, and lower per-unit costs. Specifically, output gains of 8–12% and cost reductions of approximately 5% were achievable without major capital investments, simply through process optimization. The findings underscore MATLAB’s effectiveness as both a simulation and decision-support tool, providing a pathway for Nigerian tile manufacturers to improve competitiveness, reduce waste, and enhance sustainability through data-driven process improvement strategies
simulation-based optimization, particularly with MATLAB, offers significant potential for improving manufacturing efficiency, but its application in local tile production remains limited. This study addresses this gap by exploring how MATLAB-based simulation can be employed to evaluate and enhance the performance of a tile production facility in Benin City, Edo State. The methodology involved collecting comprehensive production, machine, material, energy, and quality control data from a selected facility. These datasets were organized and converted into MATLAB struct format, enabling the development of a simulation model that replicated key stages of the production process. The model was used to run a five-year performance analysis, incorporating variables such as machine utilization, defect rates, energy consumption, and production output. Incremental optimization strategies such as adjusting batch sizes, refining firing schedules, and improving maintenance planning were introduced to assess their potential
impact on operational efficiency and cost reduction. Results from the simulation revealed gradual but consistent performance improvements over the five-year period, including increased daily output, higher machine utilization, reduced defect rates, and lower per-unit costs. Specifically, output gains of 8–12% and cost reductions of approximately 5% were achievable without major capital investments, simply through process optimization. The findings underscore MATLAB’s effectiveness as both a simulation and decision-support tool, providing a pathway for Nigerian tile manufacturers to improve competitiveness, reduce waste, and enhance sustainability through data-driven process improvement strategies
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