Introduction
In high-precision manufacturing, ensuring the production line delivers both speed and reliability is critical. A leading automotive component manufacturer, planning a new cylinder block machining line, wanted to confirm its proposed setup could meet aggressive production targets of 29,500 blocks per year (14.8 jobs per hour). The objective was not only to validate the throughput but also to explore ways to reduce buffer sizes without compromising output. To accomplish this, the client partnered with Production Modeling India (PMI) for a detailed simulation and throughput improvement study.
Client’s Challenge
- Validate whether the proposed line could consistently meet a 14.8 JPH production rate
- Minimize buffer spaces while avoiding production delays
- Understand the impact of gantry availability, which plays a key role in material transfer
- Identify potential future bottlenecks that might arise as production ramps up
Machining Line Optimization: From 14.8 to 16.5 Jobs per Hour with Strategic Buffer Planning
PMI’s Approach
PMI employed a data-driven simulation strategy tailored to replicate the proposed machining line’s performance:
Data Collection & Baseline Validation
Gathered detailed cycle time and equipment availability data and built a baseline simulation model reflecting the layout and logic of the proposed system.
Bottleneck Identification
Using throughput and WIP analysis, the team identified the top three constraints in the system likely to limit performance.
What-If Scenario Testing
Conducted experiments to analyze the effect of reducing buffer sizes and altering gantry availability to study how these changes would influence the system’s output.
Performance Analysis & Optimization
Focused on maintaining throughput above the required 14.8 JPH with optimal buffer allocation and reliable transfer systems.
Findings & Recommendations
• The proposed facility could achieve a throughput of 16.5 JPH, exceeding the target.
• Reducing buffer sizes below a critical level negatively impacted throughput, highlighting the need for balanced storage.
• Interestingly, lower gantry availability had minimal effect on overall production, suggesting system resilience.
• PMI provides insights into potential future bottlenecks, allowing for proactive planning and resource allocation.
Machining Line Optimization: From 14.8 to 16.5 Jobs per Hour with Strategic Buffer Planning
Conclusion
PMI’s simulation study not only validated the client’s production goals but also delivered a clear roadmap for operational efficiency and strategic buffer management, ensuring the new machining line is built for both performance and flexibility.
