<p>Vehicle safety components are made from forged and heat-treated steel, as they offer the best combination of strength and toughness. Manufacturing complies with multiple demands, such as variations in dimensions and mechanical properties, that are produced in various volumes and short production times, and this requires innovative production solutions to achieve the requirements. Forging companies typically operate in single-piece flow patterns in which manufacturing cells are designed to enable continuous production whilst maintaining good working conditions. Simulation can optimize adjustments when line improvements or unplanned products are scheduled and provide the best tunings based on expected time and quantities. The system can then be organized more efficiently, reducing costs, blockages, and defective production. This work presents the studies conducted in a forging plant that produces heavy-duty front-axle beams. The analyses involved data gathering and using discrete-event commercial simulation software to improve productivity and reduce bottlenecks. It was found that the heating rate of preforms must be adjusted to improve productivity by avoiding their removal when the following processing equipment is unavailable. The simulation also indicated that heat-treating can be enhanced by extending the austenizing furnace and installing a gantry crane to reduce the time involved in quenching.</p>