TESTING & VALIDATION OF A NEW INJECTION + PAINTING LINE
Stock sizing, injection batch sizing, minimum number of AGVs supermarket capacity
Increasing the number of
AGVs do not necessarily
Adding a two-position buffer before the painting lines was
founded to be key to achieve takt time. The model can also be used to test different storage locations in supermarket. Justification of the investment and cost reduction.
Working side by side with the client, the development of the model was fast and successful as it was being built and validated simultaneously. Therefore, once the 3D environment was created upon the layout, all the logic defined: AGVs routing and operation, weekly demand based on customer sequence, injection orders considering stock sizes by reference, painting according to plan, etc…
Analysis & Results
Regarding the analysis, the fulfillment of the painting. machines takt time was identified as a key requirement Different ‘What If’ scenarios were simulated considering different number of AGVs , painting plans, stock sizes order levels and injection batch sizes. The Experimenter tool of FlexSim was used to easily test these scenarios and results.
In the one of the plants of a tier1 automotive supplier, a new line in which injected parts will be painted needed to be properly dimentioned and validated. By using a FlexSim simulation model we were able to determine the production and logistics capacity and test sequencing scenarios, lot sizes and virtually any other system variable. Some of the key variables to analyze were the number of AGVs, initial stock sizes, injection batch sizes, supermarket capacity, stock locations, number and capacity of trolleys, etc. As there is a lot of interdependence between these parameters, and multiple references with different specifications (cavities, take rates, scrap, cycle time, etc.), checking the performance of the line through a parametrized simulation
An additional picking station was founded to be necessary, operators are not the bottleneck of the system and some other measures which improve the efficiency of the system were proposed and validated (capacity of 4 pallets in buffer pre-picking, 5 pallets in transit per station). As a result, the design was validated, the investment was justified and the simulation model can also be used as a guide for the PLC programmers as all the logic is validated and ready to implement. Como resultado, diseño validado, inversión justificada (importante ahorro económico), herramienta de ayuda para la programación de los PLC.
How to verify the design of a new warehousing system? How to analyze and justify the investment?