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Case Study

Here are some of our CASE STUDIES of Process Simulation with AutoMod.

(CASE-1) Automotive Paint Shop: Validation of the system

(CASE-1) Automotive Paint Shop: Validation of the system

Click to view sample movie.

output data
[ output data ]

 

Validation of the capacity of the Paint Shop, and
identification of bottlenecks.

[ Validated items ]
- Throughput
- Bottlenecks
- Storage Capacity

As a result, required throughput was not achievable and
some bottlenecks were found.

For example, control for Main Line and Re-send Line was not
consistent, which caused a problem on junction, and finally
blocked Main Line.

We prepared some countermeasures such as alternation for
stop position, priority-giving logic, etc.
Then we verified by simulation the most feasible and
recommendable system, and gave feedback to equipment
specification.

Thus we can verify / validate the control logic on planning
phase by simulation, which is one of the invaluable benefits
it provides.

(CASE-2) Automotive Assembly Shop: Study for the most feasible Numbers of Tow Truck

(CASE-2) Automotive Assembly Shop: Study for the most feasible Numbers of Tow Truck

Click to view sample movie.

Tow Truck delivers required parts to lineside.

If the number of Tow Truck is too many, each of them could
have long waiting time or idle time, which means waste.
If it's too small, delivery could be delayed and cause line
stop which will decrease the throughput.

Simulation can optimize the numbers of Tow Truck,
changing the numbers of them or some parameters (speed,
delivery logic, etc).

Simulation can consider the factors which are difficult to be
estimated manually such as:
- Waiting time at Storage for loading (making queue)
- Waiting time or deceleration at intersections / junctions
- Impact of fluctuation of inventory

Therefore the result can be more reliable than manual calculation, and it can give feedback to help developping the
plan of the system.

(CASE-3) Plastic Injection/Molding Shop of Vehicle Parts: Production Control System

(CASE-3) Plastic Injection/Molding Shop of Vehicle Parts: 
Production Control System

Click the image to view movie

image of input parameters
[ image of input parameters ]

 

image of output results and analysis
[ image of output results and analysis ]

 

In this case we developped Excel Interface to access
AutoMod model.
All the operations of simulation, such as input of parameters,
running simulation, and output of the result, can be done on
Excel Sheet.

Unlike other cases, this CASE is applied to daily production
line, not planning phase.

It validates the parametes of daily production such as:

- Production Scheduling / Arrangement
- Worker Allocation
- Inventory of molded parts
- Defect Ratio on Paint

which could change everyday, according to the demand of
their customers.

If the result of simulation does not satisfy the requried
throughput, some recommendations will be provided to
support optimization of the system.

Running simulation and changing parameters are done on
Excel Sheet, so that the operators who are not familiar with
simulation can handle it.
In this CASE there are 12 equipment for Plastic Injection,
which require 2 cranes to change the mold.

Changing mold takes about 30 minutes, so it is very
important to consider any impact for efficient production,
such as:
batch size, control of crane, production schedule.

Simulation can be user-friendly and easy with Excel
Interface, and it provides a solution for daily production with
our customer's own hands quickly.

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