Introduction
Client Organization is a global automotive industry leader specializing in the production of body-in-white closures, exhaust systems, and closure manufacturing equipment.
They provide a complete turn-key solution, offer a fully integrated production system that supports customers from product design, tool development, through mass production. The flawless execution of their Full Vertical Approach enables them to achieve short vehicle development timeframes with exceptional quality.
To quickly understand their design, a simulation study is done to ascertain the required operating parameters.
Client’s Challenge
• Conveyor rules to maintain WIP
• Recovery during major breakdowns
• Blackbox operation of subassemblies
• Batch production and changeovers on Subassemblies
Key Challenges
- Current Facility can achieve required throughput.
- Entry at paint is bottleneck.
- Recommended skid count of 70 – 90 skids
- Recommended trolley count of 358 trolleys
- 3 forklifts and 4 tow-trucks are required
Production Analysis Skid & Trolley Analysis in Car Manufacturing Industry
PMI's Approach
The study was organized in a 6-stage process:
1. Data Verification and Static analysis
Check data provided by client, analyse information and theoretically estimate the possible utilization and output from the system.
2. Conceptualization
Understand all parameters, rules and possible changes in the manufacturing system. Come up with a flexible model building method to quickly accommodate possible changes.
3. Model Building and Verification
Using Simulation software, build and check behaviour of model against static analysis.
4. Testing Scenario’s
Tweak parameters and analyse the model to bring value to current facility.
5. Results and Conclusion
Throughput target is achieved. Optimization of skid, trolley and MHE counts. Tabulate all scenario’s tested for client reference.
Static Analysis
• Analyze batch building of subassemblies based on required model mix and setup batches that can meet the target throughput.
• Machines Utilization factoring in changeovers and downtimes
Production Analysis Skid & Trolley Analysis in Car Manufacturing Industry
Finding & Recommendations
After doing analysis and evaluation following results were obtained –
• Phase 1 – Skid analysis and throughput analysis
• Machines Utilizations studied – Paint Entry is the bottleneck.
• Considering expected WIP for recovery during major breakdowns, the following shows the recommendation of 70-90 skids.
• Phase 2 – Trolley analysis. The best scenario is shown below.
• A forced delay is seen on the mainline due to long travel time of the tow-truck. It is the second bottleneck. A sensitivity nalysis is done to study benefit of improvement.
• Model is flexible to add more vehicles (Tow-trucks and forklifts), update line speeds, downtimes, changeovers and check deviation of model mix due to randomness.
