Simulation helps optimise car plant efficiency

Using Lanner WITNESS simulation software, Volvo's Gent, Belgium, plant is helping optimise plant efficiency in producing new models or revising exisitng operations.

Using Lanner WITNESS simulation software, Volvo's Gent, Belgium, plant is helping optimise plant efficiency in producing new models or revising exisitng operations.

Lanner reported that Volvo's Gent plant in Belgium is relying on WITNESS simulation software to continually optimise efficiency and productivity and maintain its reputation for quality.

Lanner said that WITNESS is helping Volvo to do the following.

* Identify the optimum approach for new or revised car manufacture for models including the V50, C30, S60 and the new XC60.

* 'De-risk' decisions.

* Maintain control of costs.

* Prove production scenarios in a virtual environment before investment is committed.

* Identify and remove blockages and 'bottlenecks' in the production process.

With a turnover of EUR 4 billion, Volvo's Gent plant produces over 200,000/year and employs 4,500 people.

products include the Volvo S40, V50, C30, S60 and the new XC60.

The plant is one of two main Volvo assembly plants and exports 97% of its production.

* Optimising efficiency - as automotive manufacturing faces eroded margins, escalating consumer expectations, competition from low-cost countries as well as the ongoing legislative landscape, Volvo's Gent plant has to operate at optimum levels of efficiency while maintaining high quality standards at all times.

The plant was the first non-Japanese company to be honoured by the Japan Institute for Plant Maintenance for its focus on quality and efficiency winning in its lifespan the Excellence Award, the Special Award and the Award for World Class Achievement.

In order to maintain, and continuously improve upon its credentials for efficiency and quality in manufacturing, Volvo relies upon simulation technology.

Simulation supports major business decisions through mapping out scenarios in a virtual environment.

In taking this approach, Volvo's Gent plant can build business cases and de-risk decisions prior to investment being committed.

* Results - for the last 10 years, Volvo has used WITNESS software as a key tool in enabling its Gent plant to respond quickly and accurately to the business demand.

These often relate to: capacity for a new model; changes in production; new legislation; future capacity; ascertaining the root cause of bottlenecks and maximising productivity (and overall profitability) of the plant.

Through accessing a comprehensive picture of production across the entire plant, inefficiencies and areas of capacity can quickly be identified and addressed to the benefit of the plant.

Simulation helps Volvo to avoid blockages and production 'bottlenecks', said Lanner to manufacturingtalk, mitigate against risk and avoid escalating costs.

It is critical to have a means of testing decisions in a virtual environment before committing investment and WITNESS really is an invaluable tool for its business.

Simulation is used when Volvo has to make any decision about the plant, said Lanner.

Whether it is production of a new car, identifying capacity for unexpected demand or ascertaining the efficiency of a particular area such as welding, painting or final assembly, WITNESS plays an important role.

* Simulation is a driver - Volvo Gent has just adopted WITNESS 2008 and is already benefitting from advanced functionality.

In particular, spreadsheet style grid editing and dashboard style views mean that Volvo can see all information and results relating to a given project.

In addition, sub-modules can easily be drilled down into at the touch of a button.

A comprehensive de-bugging functionality also helps to identify mistakes quickly, enhancing the productivity of the solution.

Volvo's wish list for improvements to the solution is always taken into account and many suggestions have been included in the new version of WITNESS 2008.

It is so important that Volvo can work collaboratively with the Lanner development team to ensure the solution continues to meet its needs now and in the future.

With only one full-time simulation expert it is imperative that Volvo's chosen simulation solution is deeply functional, flexible, responsive, and can be deployed for multiple projects at any one time.

Volvo continuously reviews the market to ensure that it is using a 'best-in-class' simulation solution and continuously concludes that WITNESS is a solution which meets its needs.

Innovation is essential in the car industry and it is integral that Volvo works with innovative tools which optimise production and maintain a reputation for quality and efficiency, as well as improving margins.

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