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Automation software
News Release from: Delmia | Subject: Delmia QUEST simulation package
Edited by the Manufacturingtalk Editorial
Team on 02 November 2001
Computer simulation solved cell problem
After a couple of months, an electronic goods manufacturing cell was underperforming, so N and R called upon Northern Technologies, which applied simulation techniques to solve the problem.
Winning a large contract to supply internal antennae for the mobile phone market proved to be not quite as straightforward as N and R Engineering's management team had hoped When production began, it became apparent that there was a problem associated with the deformation of thin aluminium wire during the forming process
This article was originally published on Manufacturingtalk on 11 May 2001 at 8.00am (UK)
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As a result, an extra operation was required in order to straighten two legs on the component so they were parallel.
After a couple of months, it became apparent that the cell was underperforming, so N and R called upon Northern Technologies, the industry owned business support and technology transfer centre based in Nelson, Lancashire.
Paul Bateson, a Project Manager at Northern Technologies, explained: "We realised that a combination of modelling the cell in DELMIA's QUEST and applying lean manufacturing techniques would help N and R improve the cell's performance.
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The U-shaped production line consisted of an automatic wire cutting machine feeding five workstations, each with a different manual operation - fly pressing, crimping, trimming, assembly and coining.
We immediately set about gathering data about the individual process times, cell layout, labour positioning, part handling and the rate at which the wirecutting machine was feeding the cell." DELMIA/QUEST is one of the most advanced discrete event simulation packages available.
Incorporating 3D graphics, and offering an additional Virtual Reality (VR) Option, QUEST is an interactive tool which allows the user to quickly produce textured, high quality models for both commercial and manufacturing applications.
QUEST is a tool capable of rigorous analysis of multiple business scenarios.
Incorporating intelligent algorithms, QUEST quickly calculates the optimum solution from a wide range of model parameter combinations and constraints.
Paul Bateson modelled a new cell layout in QUEST and performed a series of statistical simulations using the process data previously gathered.
The operators were then invited to view the various scenarios and a few tweaks were made before a final layout was agreed upon.
The result was that the U-shaped cell of operators facing outwards became a C-shaped one with operatos facing inwards, allowing them to see and talk to one another.
QUEST's ergonomic capability was utilised, scheduling time attributes for each operator task, eliminating overreaching during part transfer.
Next, the wire cutting machine was slowed so that it matched that of the longest individual operation within the cell.
It was also raised up, allowing the wires to be gravity fed into the first operation.
Then racks holding just 20 components in a standard orientation were placed a various stages of the manufacture.
Finally, Northern Technologies held training sessions with the operators.
As the new methodology involved a pull system rather than the previous push system, discipline was required as to how the upstream operators perform their task.
In particular, it was explained that if the next process downstream already has a full rack of parts, then no more parts should be produced until there is space on that rack.
Mark Stinchon, Plant Manager at N and R Engineering, commented: "Increased production capacity and more flexibility has led to our customer awarding us further contracts to supply their overseas operations in the United States and Australia.
Cell throughput has increased from around 2,250 parts per shift to 3,520 parts per shift.
At the same time, our inventory has been reduced from almost 1,000 parts to a mere 120.
The cell has improved workflow and ergonomics, with the operators actually preferring the new working conditions.
There have even been several unlooked for benefits.
The wirecutting machine no longer jams because it operates at a slower speed and quality is easier to monitor owing to the pull system's rules." Founded in 1977, N and R Engineering employs 80 people with an annual turnover of GBP 4 million.
A subcontracting engineering company, N and R operates 24 hours a day, seven days a week.
Its commercial work is broad based, including hydraulics, pneumatics, telecommunications, electrical and medical parts.
The company specialises in spool and sleeve hydraulics and has over 120 regular customers.
Northern Technologies provides high quality training, technical and business support to industry and commerce, mainly, but not exclusively, throughout the North West of England.
The organisation is industry driven and owned.
Using the latest software in association with the UK's leading suppliers, Northern Technologies offers engineering and product design support from concept development through to prototyping and the supply of production parts.
It has extensive experience in supporting companies in all aspects of getting products to the market-place and has broad knowledge of low cost development routes and rapid prototyping technology.
DELMIA develops e-business solutions for manufacturing by implementing a process-centric solution to plan, define, monitor and control production systems from single device workcell, production line, factory material flow to extended enterprise production flow.
DELMIA serves industry segments where continuous transformation and optimisation of the manufacturing processes are critical, such as: Automotive, Aerospace, Fabrication and Assembly, Electrical and Electronics, Consumer Goods, Shipbuilding.
DELMIA solutions are interoperable with major CAD, PDM and ERP systems.
DELMIATM is owned by Dassault Systemes.
All other company product or service names mentioned may be trademarks or service marks of others.
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