Simulation of an Automobile Plant for a Leading Vehicle Manufacturer – New Body and Paint Shops

March 8, 2023

Simulation of an Automobile Plant for a Leading Vehicle Manufacturer – New Body and Paint Shops


Guruprasad Tharigopula |

A leading global automotive company planned to add new body and paint shops in the facility to ramp up its production.

The expansion was planned to increase the Paint Shop capacity 1.5 times the existing capacity. Given the complexity of the Paint Shop system, the client wanted to conduct a simulation study to determine whether the proposed expansion can indeed increase the Paint Shop capacity as desired.

Key Points

  • Automobile Industry
  • AutoMOD
  • Material Flow Analysis
  • Congestion Analysis
  • Carrier Analysis

Client's Challenge

  • Identify optimum buffer requirement and carrier counts between Body and Paint, Paint and Final shops
  • Recommend conveyor layout with required number of lanes and their parameters to improve routing
  • Optimize rules between body shop and paint shop to minimize purge operations in paint shop spray booth
  • Optimize rules between paint shop and final shop to rearrange mixed up units to their original sequence

PMI's Approach

We carried out static analysis, 2D and 3D simulation to study in detail :

  • Body Shop, Paint Shop and Final Assembly separately
  • Total Plant combining each shop and intermediate vehicle handling and storing conveyors (Body-In-White Storage/ BIW and Painted Body Storage / PBS)

Findings & Recommendations

We found that the main bottleneck in the system to be the chassis line in the assembly shop with the design buffer system and carrier counts.

  • Increasing the door loop conveyor capacity by 20 units improved the throughput
  • Using the recommended number of carriers and the conveyor layout for WBS and PBS helped achieve the target throughput

Let our experts show you how our Services can support your projects!

Send a message to our team by filling out the form below. Describe your project, ask questions, or even request a bid.
An expert from our team will be in touch with you within one business day!

Want to schedule a time to speak with one of our  representatives NOW?

    Reality Capture & CAD ServicesIndustrial Engineering ServicesSimulation Modeling ServicesSafety & Quality ManagementGIS Consulting ServicesJig & Fixture DesignSteel Detailing ServicesAdvanced SoftwareTrainingOther

    EmailGoogle SearchBingWord of MouthSocial MediaEventReferralOther

    Spread the love
    Guruprasad Tharigopula

    You may also like

    Time and Motion Studies Explained

    joydeep | December 13, 2023

    Man-Machine Chart: Concept, Use and Benefits

    mbawankar | October 20, 2023

    Time Study Methods in Operations Management

    mbawankar | October 19, 2023

    What is Laser Scanning & Photogrammetry ?

    joydeep | October 6, 2023

    Consult an Expert

      Reach out to our representatives!