Simulation of a Power and Free Conveyor System for a Leading Vehicle Manufacturer

March 2, 2023

Simulation of a Power and Free Conveyor System for a Leading Vehicle Manufacturer


Guruprasad Tharigopula |

A leading global automotive company wanted to check the feasibility of their power and free conveyor system after introducing a lineup of new vehicles and find out ways to improve their system.

Key Points

  • Automobile Industry
  • Tecnomatix Plant Simulation
  • Feasibility Study
  • Bottleneck Analysis
  • Optimizing Operational Rules

Client's Challenge

  • Check feasibility of the system to meet target production with new model mixes
  • Identify and alleviate any bottlenecks in the conveyor system
  • Study the impact of system output on the percentage of vehicles that are loaded on the conveyor system

PMI's Approach

  • We modeled the conveyor system in 3D using Tecnomatix Plant Simulation
  • Operating rules for loading and carrier routing in the system were defined and improved through simulation
  • System throughput, time-in-state graphs, number of vehicles in the system were tracked

Findings & Recommendations

We found that the target was not achieved even when only 20% of the vehicles were loaded on the system

Lack of hangers at one of the loading stations lead to filling up of buffer and causing blockage at a production shop

  • Relocating a portion of another underutilized buffer helped achieve throughput when 40 to 80 % of the vehicles were loaded onto the conveyor

A paint shop system where vehicles are unloaded from the conveyor system was running at its full capacity

  • Installation or expanding the existing paint shop would allow the conveyor system to handle 100% of the vehicle being loaded

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