Weekend buffer simulation

Simulate a car body buffer in order to improve its management

Automotive SIMULATION/COMMISSIONING/AFTER-SALES AIM

To compare the number of bodies that can be supplied by the buffer, simulating current management with regard to several experiments and then applying any improvements.

The aim was to simulate buffer management, with a view to applying improvements before intervening in the plant.
The main problem they had diagnosed was that all the bodies came out of the buffer at the same time, and this caused bottlenecks as the bodies could not come out again until the outgoing transfer was completely emptied.
The main hypotheses simulated are to place intermediate conveyors in the output transfer, in order to finish the transit of the bodies before output, and to change the output strategy. The bodies will come out by model request and counter, rather than bringing them all out at the same time.
Once the simulation was completed, the results were extracted and used to decide whether or not to modify the system. Thanks to these improvements, the number of bodies supplied by the buffer increased by 5.4%, i.e. 40 more bodies per shift.

TOOLS

PROJECT BENEFITS

Optimum system programming.
Flexibility to try out different configurations before investing in mechanics or programming.
Hypothesis testing.

The customer was very satisfied. The simulation led to investment to change the programming of the PLCs that control the buffer, and it is currently working with the new management tested in the simulation.