Simulation of an End-of-Line Testing Area for a Leading Vehicle Manufacturer

March 1, 2023

Simulation of an End-of-Line Testing Area for a Leading Vehicle Manufacturer


Guruprasad Tharigopula |

A leading global automotive company wanted to right-size the number of drivers required for maneuvering vehicles in the End-of-Line section of its automobile production ensuring the desired target is met.

Key Points

  • Automobile Industry
  • AutoMOD
  • End of Line
  • Driver Utilization
  • Capex Study

Client's Challenge

  • Identify and alleviate bottlenecks in the system
  • Recommend ideal number of car drivers, process stations and parking spaces in the End-of-Line section
  • Analyze the impact of repair rates on system throughput

PMI's Approach

  • The station cycle times were statistically modeled based on real-time data from client
  • The detailed process was modeled in Simul8
  • The queue sizes, driver and equipment utilizations were studied while varying first-time-through rates

Findings & Recommendations

The system was able to produce just 65% of its target production.

We found that the number of calibration test drivers were the first constraint in the system

  • Addition of 2 more drivers improved the throughput by 30%

The number of body repair stations were the second constraint in the system

  • Improving the cycle time by 50% by addition of labor ensured the throughput is met

A First-time-through sensitivity test showed that a minimum of 75% vehicles should clear the inspection test to meet target production

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