Simulation of a Sequencing Buffer for a Leading Vehicle Manufacturer
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A leading global automotive company wanted to improve its operations by studying the feasibility of a buffer system in supporting the required sequencing constraints at Final Assembly. Sequencing is one of the most influential production planning processes that helps produce multiple models/ variants on a shared manufacturing setup efficiently.
Key Points
- Automobile Industry
- Simul8
- Sequence Optimization
- Feasibility Study
- Logic Optimization
Client's Challenge
- Check feasibility of a buffer system to lift sequencing constraints
- Identify the number of violations in sequence and recommend ways to minimize the same
PMI's Approach
- We modeled the detailed sequencing setup in Simul8
- System throughput, time-in-state graphs for transfers, paint and final shops, buffer variations and the exit sequence were tracked
- Analysis was carried out to find the main reasons for sequence violations
Findings & Recommendations
We found that around 300 vehicles / day violated the sequence.
Three main parameters affecting the violations were identified and studied separately
- Recommended revision in model mix so that the number of violations is reduced without affecting the desired product flexibility
- Optimum size of the sequencing buffer system was identified to eliminate violations
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