Integration of Simulation in Strategic Decision-Making in Dairy Industry

In the context of Industry 4.0, the challenge of improving process efficiency and decision-making in the dairy industry remains critical. This study addresses this problem by evaluating the application of Flexsim simulation software to optimize a dairy plant’s production processes. The main objective of the work is to demonstrate how simulation can enhance production efficiency and reduce material blockages. The methodology involved developing a detailed simulation model of the production line using Flexsim, where multiple scenarios were analyzed to identify bottlenecks and optimize resource allocation. Key results showed an 11.11% improvement in production efficiency and a reduction in blocked material from 36.09 to 10.48%. These findings highlight the ability of Flexsim to support tactical decision-making based on precise and real data. Despite some limitations, such as the complexity of model development, the study concludes that simulation is an essential tool for continuous improvement and maintaining competitiveness in the dairy industry, with potential applications in various industrial sectors. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2026.