Simulation of a Door Assembly Line for a Leading Vehicle Manufacturer

March 2, 2023

Simulation of a Door Assembly Line for a Leading Vehicle Manufacturer


Guruprasad Tharigopula |

A leading global automotive company wanted to improve its operations, setup optimum number of carriers in its Door assembly area to meet its increased production target.

Key Points

  • Automobile Industry
  • AutoMOD
  • Bottleneck Analysis
  • Buffer Analysis
  • Carrier Analysis

Client's Challenge

  • Identify and alleviate bottlenecks in the system
  • Recommend ideal number of door hangers, buffer sizes and other operational changes to achieve target production

PMI's Approach

  • We modeled the detailed door lines and main lines in AutoMOD
  • System throughput, time-in-state graphs, number of vehicles in the system were tracked

Findings & Recommendations

We found that there was loss in production due to downtimes, particularly whenever a specific model type arrived

  • Recommended addition of a mezzanine buffer just before an unloading station which proved to eliminate blockages caused during downtimes

Due to a routing constraint, a vehicle required 3 minutes of travel time which lead to loss in throughput

  • Recommended two more cross transfers to be added in the system before the unloading station

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