Product category:
CAD/CAM systems (not machine tools)
News Release from: Delmia | Subject: QUEST discrete event simulation software
Edited by the Manufacturingtalk Editorial
Team on 30 August 2001
Simulation used in quest for best
process
Late last year, Corus Engineering Steels approached AMTRI to create the optimum manufacturing methods, machine tools and operational sequences to produce automotive axles.
Late last year, Corus Engineering Steels approached AMTRI to create the optimum manufacturing methods, machine tools and operational sequences to produce automotive axles AMTRI, a specialist manufacturing consultancy since the 1950s, designed a methodology new to established axle suppliers and modelled a line capable of a maximum 700,000 annual throughput using Delmia's QUEST system
This article was originally published on Manufacturingtalk on 11 May 2001 at 8.00am (UK)
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We quickly realised that each stage of the process threw up several "what ifs" and we needed help to build a fully automated, lights out, fully costed, workable solution." Bob Lloyd, Project Manager for AMTRI, said: "Our experience told us that the best approach would be to first make the parts and then weld them together.
Next, we investigated possible machines, the process in detail, manning levels, layout and cycle times.
Our goal was a 30 second cycle time.
"By selecting the best machines for the application, we began to develop a solution, which would be a surprise to people with an automotive background.
However, the system integration was far from straightforward, as each of the key machines required a different method of part presentation.
Balancing our clients' different parameters would have proved impossible without QUEST." To validate the various permutations, AMTRI modelled the system in QUEST discrete event simulation software using CAD data supplied by the machine manufacturers, who also provided process cycle times, normal methods of loading and unloading, tool change and maintenance requirements.
Next, the machines were laid out to a feasible floor plan, taking into account operator access, machine connectivity and machine redundancy.
The logic of interconnecting conveyor and transport elements were then added, together with their characteristics and associated parts, such as buffers.
Subsequently, the model was extended to include some tool changing, labour requirements and input pallet buffering, as well as rudimentary forklift requirements.
It was then possible to simulate breakdowns and analyse bottleneck build-up.
"For example", he continued, "we analysed both fixed coil induction heating and moving coil induction heating.
We were able to prove that the moving coil method was both faster and cheaper.
Using it changed the whole process, which is the luxury you have when you start from first principles.
Just as importantly, QUEST is also a communication tool, making it easy for everyone involved to fully understand what is being considered and why.
The parts assume different colours at different stages in the process and the system can analyse any aspect at any stage.
As a result, we were able to identify the one shift a week which required four men to change the friction welding tools.
Previously, it had been assumed that four men would always be needed.".
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