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