Simulation of an Automated Closure line for a Leading Supplier – New Body Shop

March 2, 2023

Simulation of an Automated Closure line for a Leading Supplier – New Body Shop


Guruprasad Tharigopula |

A leading line builder designed a new body shop line for its client in the automobile industry and wanted to check the feasibility of its proposed design and identify minimum buffer sizes to achieve target production


  • Automobile Industry
  • Tecnomatix Plant Simulation
  • Work Cell Simulation
  • Bottleneck Analysis
  • Downtime Analysis

Client's Challenge

  • Check feasibility and validate the proposal
  • Identify and alleviate bottlenecks in the system
  • Identify minimum buffer sizes required to achieve target production

PMI's Approach

  • The detailed process was modeled in Tecnomatix Plant Simulation
  • The operating sequences and downtimes from the client were provided through an Excel interface to the simulation
  • The buffer variation, throughput and time-in-state graphs were recorded and studied

Findings & Recommendations

The system was operating only at 85% of its designed capacity

We were able to identify the first bottleneck to be the buffer between an assembly and an inspection station

  • The minimum buffer requirement was suggested through buffer sensitivity analysis
  • The throughput loss due to selecting a smaller buffer was demonstrated

The second bottleneck of the system was the operating sequence of a material handling robot

  • The cycle time of the handling robot needed to be reduced or the operating sequence had to be modified

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    Guruprasad Tharigopula

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