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

Published by Guruprasad Tharigopula on March 2, 2023

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

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

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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