Abstract
Lean and Swift-Even-Flow (SEF) operations are compared in the context of sorting facilities. Lean approaches tend to attack parts of their processes for improvement and waste reduction, sometimes overlooking the impact this will have on their overall pipeline. A SEF approach on the other hand is driven by a desire to reduce variations by enabling the practitioner to visualise himself as the material that flows through the system thus unearthing all the problems that occur in the process as a whole. This study integrates Discrete Event Simulations (DES) into the lean and SEF framework. A real world case study with high levels of variations is used to gain insights and to derive relevant simulation models. The models were used to find the optimal configuration of machines and labour such that the operational costs are minimised. It was found that DES and SEF have a common basis. Lean processes as well as SEF processes both converge to similar solutions. However, SEF arrives faster at a near optimum solution. DES is a valuable tool to model, support and implement the lean and SEF approach. The SEF approach is superior to lean processes in the initial phases of a business process optimisation. The primary novelty of this study is the usage of DES to compare the lean and SEF approach. This study presents a systematic approach of how DES and optimisation can be applied to lean and SEF operations.