Production Analysis Skid & Trolley Analysis in Car Manufacturing Industry

February 1, 2024

Production Analysis Skid & Trolley Analysis in Car Manufacturing Industry


mbawankar |

Client Organization is a global automotive industry leader specializing in the production of body-in-white closures, exhaust systems, and closure manufacturing equipment.

They provide a complete turn-key solution, offer a fully integrated production system that supports customers from product design, tool development, through mass production. The flawless execution of their Full Vertical Approach enables them to achieve short vehicle development timeframes with exceptional quality.

To quickly understand their design, a simulation study is done to ascertain the required operating parameters.

Key Points

  • Current Facility can achieve required throughput.
  • Entry at paint is bottleneck.
  • Recommended skid count of 70 – 90 skids
  • Recommended trolley count of 358 trolleys
  • 3 forklifts and 4 tow-trucks are required

Client’s Challenge

  • Random Sequence of products on mainline
  • Conveyor rules to maintain WIP
  • Recovery during major breakdowns
  • Blackbox operation of subassemblies
  • Batch production and changeovers on Subassemblies

PMI's Approach

The study was organized in a 6-stage process:

  • Data Verification and Static analysis
  • Conceptualization
  • Model Building and verification.
  • Testing Scenario’s
  • Results and Conclusion

Data Verification and Static analysis – Check data provided by client, analyse information and theoretically estimate the possible utilization and output from the system.

Conceptualization – Understand all parameters, rules and possible changes in the manufacturing system. Come up with a flexible model building method to quickly accommodate possible changes.

Model Building and Verification – Using Simulation software, build and check behaviour of model against static analysis.

Testing Scenario’s – Tweak parameters and analyse the model to bring value to current facility.

Results and Conclusion – Throughput target is achieved. Optimization of skid, trolley and MHE counts. Tabulate all scenario’s tested for client reference. 

Involvement of Associates

  • PMI – 1 Project Manager, 1 Engineer.
  • Client – 2 Project coordinators.

Static Analysis

  • Analyze batch building of subassemblies based on required model mix and setup batches that can meet the target throughput.
  • Machines Utilization factoring in changeovers and downtimes

Analyze Batch Building of Subassemblies Dashboard

Finding & Recommendations

After doing analysis and evaluation following results were obtained –

  • Phase 1 – Skid analysis and throughput analysis.
  • Machines Utilizations studied – Paint Entry is the bottleneck.

Graph Chart and Table

  • Considering expected WIP for recovery during major breakdowns, the following shows the recommendation of 70-90 skids.

Breakdown Table

  • Phase 2 – Trolley analysis. The best scenario is shown below.

Phase 2 - Trolley Analysis

  • A forced delay is seen on the mainline due to long travel time of the tow-truck. It is the second bottleneck. A sensitivity analysis is done to study benefit of improvement.

Simulation Results

  • Model is flexible to add more vehicles (Tow-trucks and forklifts), update line speeds, downtimes, changeovers and check deviation of model mix due to randomness.



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