Simulation of a Door Assembly Line for a Leading Vehicle Manufacturer
February 1, 2024
Simulation of a Door Assembly Line for a Leading Vehicle Manufacturer
mbawankar |
A leading global automotive company wanted to improve its operations, setup optimum number of carriers in its Door assembly area to meet its increased production target.
Key Points
- Automobile Industry
- AutoMOD
- Bottleneck Analysis
- Buffer Analysis
- Carrier Analysis
Client's Challenge
- Identify and alleviate bottlenecks in the system
- Recommend ideal number of door hangers, buffer sizes and other operational changes to achieve target production
PMI's Approach
- We modeled the detailed door lines and main lines in AutoMOD
- System throughput, time-in-state graphs, number of vehicles in the system were tracked
Findings & Recommendations
We found that there was loss in production due to downtimes, particularly whenever a specific model type arrived
- Recommended addition of a mezzanine buffer just before an unloading station which proved to eliminate blockages caused during downtimes
Due to a routing constraint, a vehicle required 3 minutes of travel time which lead to loss in throughput
- Recommended two more cross transfers to be added in the system before the unloading station
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