Volume3, Issue 1, Jan 2025 International Journal of Modern Science and Research Technology

ISSN No- 2584-2706

Improvements in the Production Line

of the Cygnus Industries in Corporate
using Promodel Simulation Software
Jeffrey L. Cacho
Industrial Engineering Department,
Quezon City University

Abstract
The use of Promodel simulation software is a be a powerful tool for improving the production
powerful tool for improving the production line of line of a manufacturing company such as Cygnus
Cygnus Industries Incorporated. This abstract Industries Incorporated. It can help identify
provides an overview of how Promodel can be In efficiencies, bottlenecks, and areas for
used to identify inefficiencies and bottle neck sin improvement, leading to increased productivity,
the production process, test different scenarios for reduced costs, and improved profitability.
improvement, and implement changes that result
in increased efficiency and reduced costs. By B. Company Profile
continuously monitoring the performance of the Cygnus Industries Incorporated is one of the
production line, Cygnus Industries can further Philippines' oldest and leading privately owned
optimize its processes and increase profitability. flexible packaging companies. Since its inception
This approach provides a data-driven method for in 1968, the company has evolved under a single
improving the production line, resulting in a more management and has been serving both the
streamlined and efficient production process for Filipino and Regional Markets for well over four
the company. Overall, the use of Promodel decades. They strongly believe that through
simulation software can help Cygnus Industries to continuous investment in their people and in their
stay competitive in its industry and provide high- technology, they can provide both high-quality
quality products to its customers. packaging and excellent value to all of their
clients.
Keywords: promodel, production line, Through their vast operations, we have developed
efficiencies, simulation, process extensive capabilities, technology platforms, and
business concepts. Their manufacturing facility
I. Background encompasses the entire range of flexible
A. Background of the Study packaging production. The seinclude design
The goal of a simulation study for the production preparation, cylinder manufacturing, gravure
line of Cygnus Industries Incorporated would be printing, lamination, metallization, film
to identify opportunities for improvement in the extrusion, and film finishing in bags, rolls, stand-
manufacturing process. This could involve up pouches, and sachets.Their in-house
modeling the current production line system and capabilities ensure the highest control of product
analyzing the efficiency, productivity, and quality, development, and production while
throughput, and then testing different scenarios to ensuring on- time delivery to clients.
identify improvements.
C. Objectives of the Study
A simulation study using Pro Model software can Across all industries, manufacturers are being

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 Volume3, Issue 1, Jan 2025 International Journal of Modern Science and Research Technology
ISSN No- 2584-2706

Pushed to re-evaluate the in operations. The goal number of defects.

of the production line is to increase production
efficiency and quality (Sciemetric, 2022). This research is made to provide crucial
Here are the following objectives of the study: information and knowledge which is beneficial to
the following:
1. Improve the company’s production layout.
2. Identify and propose production Manufacturers
alternatives. This data gathered will benefit the manufacturers
3. Point out the number of outputs and a in terms of identifying and learning other
possible number of defects. production alternatives which would help them in
increasing production efficiency and quality.
D. Scope and Limitation
The scope of using Promodel simulation software IE Students
for improvements in the production line is to The study will serveas advanced knowledge for
analyze and optimize the existing manufacturing their studies and will help them understand how
process to increase efficiency, reduce production using promodel simulation works when it comes
time, minimize costs, and improve overall to the production line.
productivity. This can be achieved by creating a
virtual model of the production line using To Future Researchers
Promodel software and simulating the production This will serve as their basis and guide on
process to identify potential bottlenecks, evaluate conducting another study about the Improvements
different scenarios, and test various improvement in the production line, using the promodel
strategies. The software allows for simulation software. The study would give them
experimentation with different layouts, more ideas and knowledge about the latter.
workloads, and configurations to identify the best
solutions for improving the production line. F. Review of Related Literature
Gwiazda, Sękala, Banaś, (2017) The advantages
While Promodel simulation software can be an of performing different scenarios of production
effective tool for improving the production line, problems solving caused the increase of the
there are some limitations to its use. Firstly, the frequency of using the simulation models in the
accuracy of the simulation results depends production process improvement. These can be
heavily on the quality and accuracy of the data used in various areas, i.e. in the production
used to build the model. If the data is incomplete process efficiency improvement by increasing the
or inaccurate, the simulation may not reflect the machine work in gperiod by manipulating only
real-world production process accurately. the production batches data.
Secondly, the software can only model what is
explicitly programmed into the simulation, and it Oluwole O. Akinola, Alaba F. Oyedele, Olalekan
may not be able to capture all the complexities S. Fatoki (2017) The study found that the
and nuances of the actual production process. company was experiencing production bottle neck
Finally, the software may require specialized sthatled to longlead times, high levels of work-in-
knowledge and training to use effectively, which progress inventory, and low productivity. To
can be a limiting factor for some organizations. addressthese issues, the company used Promodel
simulation software to model its production line
E. Significance of the Study and identify opportunities for improvement. The
The reason for gathering the data is to improve, simulation results showed that by making changes
identify, propose production alternatives, and to the layout of the production line and the
point out the number of outputs and a possible scheduling of production activities, the company
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 Volume3, Issue 1, Jan 2025 International Journal of Modern Science and Research Technology
ISSN No- 2584-2706

could significantly reduce ledtimes and work- in- leading to increased productivity and reduced
progress inventory, while increasing productivity. costs.
The study concludes that Promodel simulation
software is a valuable tool for identifying M.C. Cruz et al. (2019). The study aimed to
opportunities to improve production line improve the production line efficiency of a
performance. Philippine manufacturing company by using
Promodel simulation software. The researchers
Rosienkiewicz et al., (2018) Simulation models created a computer model of the production line,
are a symbolic interpretation of the input-output including the different machines and processes
relationship of real processes, which are involved. They then used the software to simulate
represented by symbols and mathematical different scenarios and analyze the performance
relations. of the production line under different conditions.
Based on the results of the simulations, the
Seyyed Ahmad Hoseini, Seyed Javad Mirzapour, researchers proposed several improvements to
Ali Mohammad Kimiagari, and Alireza Alinezhad the production line, such as adjusting machine
(2015) The study found that the company was settings, changing the sequence of operations,
facing challenges wi the bottlenecks and delays in and implementing quality control measures. The
its production line, which were leading to study found that the proposed improvements led
increased costs and decreased productivity. To to a significant increase in the production line's
address these issues, the company used ProModel efficiency, as measured by the number of units.
simulation software to model its production line produced per hour. The authors concluded that
and identify opportunities for improvement. The simulation modeling using Promodel software is
simulation results showed that by adjusting the an effective tool for optimizing production
production schedule and reducing changeover processesandimprovingoverallefficiencyinmanuf
times, the company could significantly increase acturing companies
productivity and reduce costs. The study
concludes that ProModel simulation software is J. W. Lim, J. G. Lee, J. G. Kim, J. S. Kim, and E.
an effective tool for optimizing production lines in J. Park (2017) the Philippine electronics
the food industry. manufacturing industry using Promodel
simulation software to identify ways to
Ahmed M. El-Kamel, Ahmed R. El-Zohairy, improvethe production line.They conducted a
Mohamed A. El-Kholy, Mohamed S. El-Sharkawy simulationof the production line to determine the
(2014) They use ProModel simulation software to bottleneck and improve the efficiency of the
model the existing production line and identify production line. The study showed that by
areas for improvement. They then propose and reducing the waiting time and queue time, the
evaluate various improvements scenarios using the production line's overall efficiency improved.
simulation model. The authors found that using This research provides insights into how the use
ProModel simulation software helped them to of Promodel simulation software can help
optimize the production line by reducing the cycle improve the production line in the Philippines.
time and increasing the production rate. They also
identified bottlenecks and areas of waste, which R. Borromeo (2018-) The study found that the
allowed them to develop solutions to increase company's producti online was experiencing
efficiency and reduce costs. Overall, this literature bottle necks and delays due to poor production
shows that using Promodel simulation software planning and scheduling, inadequate staffing, and
can be a powerful tool for improving the unreliable machinery. To address the seissues, the
production line in manufacturing companies, researchers developed a simulation model of the

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 Volume3, Issue 1, Jan 2025 International Journal of Modern Science and Research Technology
ISSN No- 2584-2706

production line using Promodel software. They optimizing the production schedule, and
then used the model to test various scenarios and implementing buffer stocks. The results showed
identify the most effective solutions to improve that the proposed improvements could increase the
efficiency. The results of the study showed that plant's production capacity and reduce its
by implementing the proposed solutions, the production lead time. The study demonstrated the
company was able to increase its production rate effectiveness of simulation-based optimization in
by 23% and reduce its cycle time by 18%. The improving the production line of a manufacturing
company also experienced significant cost plant in the Philippines, particularly in identifying
savings due to the reduction of machine bottlenecks and proposing solutions for
downtime and the elimination of excess improvement.
inventory. Overall, the study demonstrated the
effectiveness of using Promodel simulation II. Methodology
software in improving the production line A. Research Method Used
efficiency of local companies in the Philippines. This research method statement outlines the
approach to be used for gathering data through
A L. Tan, M. T. Viloria, and J. B. Silvestre, (2021) interviews, meetings, and Promodel simulation
In the study, the researchers aimed to optimize the software. The purpose of this research is to identify
manufacturing process of a Philippine automotive improvements that can be made in the production
company using simulation modeling. They utilized line of Cygnus Industries Incorporated using
Promodel simulation software to develop a model Promodel simulation software. The research aims to
that mimics the company's production line, and explore the current production process, identify
then evaluated several scenarios to identify the best bottlenecks and inefficiencies, and propose
process improvement options. The findings of the improvements to enhance productivity and
study showed that the use of simulation modeling efficiency.
with Promodel software can significantly improve
the production line of the Philippine automotive The data collected will be analyzed using content
company. Specifically, the simulation results analysis and statistical analysis to identify
demonstrated that increasing the number of bottlenecks and inefficiencies in the production line
operators and adjusting the production rates of and propose improvements. The research will be
certain stations can reduce bottlenecks and increase conducted in accordance with ethical guidelines for
the overall efficiency of the manufacturing process. research involving human participants, and the
Overall, this literature highlights the effectiveness confidentiality of the participants will be ensured.
of Promodel simulation software in optimizing
production line processes in the Philippines, B. Data Collection
specifically in the automotive industry. The researchers made a letter of request for
approval to gather data about improvements in
Monique Janelle A. Mapalo, Marielli U. Boquiren, the production line of Cygnus Industries
and Pauline Mae B. Gan (2019) The study aimed to Incorporated. One researcher has relatives in a
optimize the production line of a cement CII company where we have been able to find the
manufacturing plant in the Philippines using information that we need to identify the specific
Promodel simulation software. The authors used the aspects of the production line that need to
simulation model to evaluate the performance of improve, such as throughput, cycle time,
the production line and identify bottlenecks that efficiency, or resource utilization. It is important
hindered the plant's efficiency. They then proposed to ensure that the data-gathering procedure is
and evaluated various scenarios for improvement, conducted in a systematic and objective manner
such as increasing the number of cement silos, to obtain reliable and accurate data that can be

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used to inform the decision-making process. reducing bottlenecks, and maximizing

productivity.
C. IE Tool Used E. Improved Quality: A Pro Model can help in
Using simulation software such as promodel can identifying potential quality issues and
provide numerous benefits for improving the implementing measures to prevent them. By
production line of Cygnus Industries simulating various production scenarios, the
Incorporated. A powerful tool for improving tool can help in identifying potential quality
production efficiency, reducing costs, identifying issues before they occur, reducing the risk of
defects and product recalls.
In summary, a Pro Model is an essential IE tool
that can provide valuable insights into the
production process of a company. By identifying
and eliminating inefficiencies and optimizing
resource utilization, a Pro Model can help reduce
costs, improve quality, and increase the overall
efficiency of the production process.

III.Analysis
A. Existing Layout
risks, and improving quality.
The figure above shows the simple existing layout
Here are some of the benefits of using a Pro of the company where in this figure the
Model in the production of a company: researchers only included one machine per
A. Improved Efficiency: A Pro Model can
process just to satisfy the use of the simulation
simulate various production scenarios and tool.
provide data- driven insights to improve the
efficiency of production processes. This can
result in better resource utilization, reduced
cycle times, and improved throughput.
B. Cost Reduction: By identifying and
eliminating wasteful activities in the
production process, a Pro Model can help
reduce costs associated with labor, inventory,
and equipment maintenance.
C. Capacity Planning: A Pro Model can simulate
various production scenarios and provide
insights into the required capacity to meet the
demand. This helps in capacity planning, The figure above shows the average capacity of
ensuring that the company has the necessary each machine, as well as the number of hours in a
resources to meet customer demand without shift, the total entries, average time per entry,
in curring additional costs. average contents, maximum contents, current
D. Optimal Resource Utilization: A Pro Model contents, and percentage of utilization of the
can help in identifying optimal resource existing layout.
utilization by analyzing the performance of
each resource in the production process. This B. Proposed Solution:
can help in allocating resources efficiently, As seen in the existing layout, there are no
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ISSN No- 2584-2706

inspections after each procedure giving more contents, and percentage of utilization for the
possible rejects before storing. The proponents first alternative. Alternative 2
proposed adding an inspection for each procedure An alternative scenario for improving the
to minimize defects or reject. Additionally, the production line of Cygnus Industries
researcher’s added a set of machine stomaximize Incorporated using Promodel simulation
production every shift. software could involve the following steps:

C. Data Analysis: A. Identifying key areas for improvement:

Cygnus Industries produces high-quality Begin by assessing the production line to
packaging for different markets locally and determine where inefficiencies and
regionally in the Philippines. The manufacturing bottlenecks occur. This could involve
facility encompasses the entire range of flexible gathering data on production output,
packaging production including printing, processing times, and workloads.
lamination, and slitting. For all production B. Creating a virtual model: Use Promodel
procedures, there is one operator per machine. software to create a virtual model of the
There are 2 machines for printing, 2 machines for production line. This will allow you to
lamination, and 1 slitting machine. The number simulate various scenarios and identify
of produced products per printing machine opportunities for improvement.
averages 19,389 kg. There are two types of C. Testing different scenarios: Use the virtual
laminations in the production which are model to test different scenarios, such as
dry/solvent-free lamination and extrusion changes to the layout of workstations,
lamination with an average of 174,546.7 meters adjustments to staffing levels, and
of products. For the last machine, the slitting improvements to supply chain logistics. This
machine produces an average of 12,058.11 kg of will allow you to see the impact of each
products. scenario on production output and costs.
D. Analyzing results: Evaluate the results of each
D. Alternative 1 scenario to determine which changes are most
The figures above show the information for the effective in improving production efficiency
first alternative. The first figure is where the and reducing costs.
E. Implementing changes: Based on the results
of the simulation, implement the changes that
are most effective in improving the
production line.
F. Monitoring performance: Continuously
monitor the performance of the production
line to ensure that the change sare achieving
researchers added a set of machines for the desired results. Make adjustments as
Production. The second figure shows the necessary to further improve efficiency and
locations where the average capacity of each reduce costs.

By following these steps, Cygnus Industries

Incorporated could use Promodel simulation
software to identify and implement
machine, as well as the number of hours in a improvements to its production line, result in gin
shift, the total entries, average time per entry, increased efficiency and profitability.
average contents, maximum contents, current

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E. Alternative 3 Incorporated. By creating a virtual model of the

production line and simulating various scenarios,
the company can identify inefficiencies and
bottlenecks, test different solutions, and
implement changes that result in increased
efficiency and reduced costs. Continuously
monitoring the performance of the production
line allows Cygnus Industries to make further
adjustments and optimize its processes for
maximum profitability. By taking a data- driven
approach to production line improvements,
Cygnus Industries can stay competitive in its
industry and provide high-quality products to its
customers.

Recommendation:
A. Based on the alternatives proposed, the
company will need to add machines and on the
The figure above shows the production line of contrary, the work force will also be increased.
Cygnus with the proposed alternatives to improve The calculation for the projected number of
the company’s production and decrease defects by personnel will be required.
adding inspection after the printing process. This B. Adding machines can also add another cost for
can help the company maximize its profits and the company. This proposal can maximize the
produce products with minimal waste. number of products that can be produced per
shift but cost- benefit analysis anb essential to
IV. Summary: compare whether such intervention or changes
Based on the scenario provided, the use of is necessary.
Promodel simulation software can help Cygnus C. The researchers cannot gather data regarding
Industries Incorporated to improve its production the accurate size of the production facility.
line by identifying inefficiencies and bottlenecks, Hence, it is use full to know the right size of
testing different scenarios, and implementing the facility to be able to execute the proposed
changes that lead to increased efficiency and alternatives well.
reduced costs. By continuously monitoring the
performance of the production line, Cygnus Acknowledgment:
Industries can further optimize its processes and The author would like to express deep and
increase profitability. Overall, the sincere gratitude to our Lord God for providing
implementation of Promodels emulation software us with the strength and wisdom that we need to
can provide a data-driven approach to improving actualize the success of this study. We can ask
production processes, resulting in a more for no more than his blessings according to His
streamlined and efficient production line for the will.
company.

Conclusion:
In conclusion, using Promodel simulation
software provides a powerful tool for improving
the production line of Cygnus Industries

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