Using system dynamics in a discrete‐event simulation study of a manufacturing plant

Purpose – To provide an example of the use of system dynamics within the context of a discrete‐event simulation study. Design/methodology/approach – A discrete‐event simulation study of a production‐planning facility in a gas cylinder‐manufacturing plant is presented. The case study evidence incorporates questionnaire responses from sales managers involved in the order‐scheduling process. Findings – As the project progressed it became clear that, although the discrete‐event simulation would meet the objectives of the study in a technical sense, the organizational problem of “delivery performance” would not be solved by the discrete‐event simulation study alone. The case shows how the qualitative outcomes of the discrete‐event simulation study led to an analysis using the system dynamics technique. The system dynamics technique was able to model the decision‐makers in the sales and production process and provide a deeper understanding of the performance of the system. Research limitations/implications – The case study describes a traditional discrete‐event simulation study which incorporated an unplanned investigation using system dynamics. Further, case studies using a planned approach to showing consideration of organizational issues in discrete‐event simulation studies are required. Then the role of both qualitative data in a discrete‐event simulation study and the use of supplementary tools which incorporate organizational aspects may help generate a methodology for discrete‐event simulation that incorporates human aspects and so improve its relevance for decision making. Practical implications – It is argued that system dynamics can provide a useful addition to the toolkit of the discrete‐event simulation practitioner in helping them incorporate a human aspect in their analysis. Originality/value – Helps decision makers gain a broader perspective on the tools available to them by showing the use of system dynamics to supplement the use of discrete‐event simulation.