Simulation of a Sequencing Buffer for a Leading Vehicle Manufacturer

March 2, 2023

Simulation of a Sequencing Buffer for a Leading Vehicle Manufacturer


Guruprasad Tharigopula |

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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