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Discrete‐event simulation (DES) and disturbance reduction techniques are a combination for improving efficiency in manufacturing systems. The DES modelling allows different tests to be carried out by step‐by‐step alteration. The use of manufacturing improvement techniques should be combined for best results. The changes in disturbances will show us different alternatives in output of the manufacturing system. Two case studies have been drawn up to study the possibilities for disturbance reduction in manufacturing systems by using DES with the proposed method for improved overall manufacturing efficiency. The case studies showed an improvement of output of 14 per cent and 18 per cent, respectively.

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