Automotive Facility Study (Body Shop)
University of Michigan Steel Detailing
February 2, 2023
Automotive Power and Free System
February 3, 2023
AUTOMOTIVE INDUSTRY\Design (Process Flow) validation
Process Flow Design Validation - Body Shop
Key Points
- Identification of potential bottlenecks in
proposed process flow - Redesigning of process flow to alleviate
bottlenecks
Client's Challenge
- The body shop plans to introduce new model C while
producing existing models A,B - Each body type requires its own special pallet type
- the proposed empty pallet release process flow to:
1. Ensure pallets are released efficiently in production
sequence while maintaing current production levels
2. Minimize empty pallet set-asides
PMI's Approach
- Analysis of Data and Verification of Baseline Model
- Identification of bottleneck by measuring pallet set asides in return loop section
Findings & Recommendation
- Proposed process flow was ineffective because:
- Facility has to manually “set-aside” excess B type pallets to
alleviate blockage(see Fig. 1) - Revised the process flow in pallet return loop to minimize
manual set-asides(see Fig. 2) - Cost effective solution - 25% savings in buffer space while
maintaining current production - Revised process flow found to be able to handle up-to 20%
variation in product mix(see Fig. 3)
