Final Report For Responsive Automotive Manufacturing Plant



Download 1.02 Mb.
Page1/2
Date19.05.2018
Size1.02 Mb.
#49182
  1   2
Final Report For

Responsive Automotive Manufacturing Plant
Dr. Ken Young

Warwick Manufacturing Group



  1. Executive Summary


A responsive automotive manufacturing plant producing a large range of vehicles with a dynamic demand profile has been simulated using discrete event simulation software. The facility is based on a matrix structure and a modular construction paradigm. Results show that it is possible to achieve high levels of equipment utilisation while building a large range of vehicles through a single facility and that this gives high levels of volume flexibility for all models. Other benefits can also be realised from this approach including-

Attempts to compare costs for such a facility with similar traditional methods have however been less successful. While published figures for existing plants clearly show the losses incurred by an inability to handle large demand fluctuations it has been impossible to cost up a generic production system. Companies have either been unwilling or incapable of divulging cost models for existing facilities let alone a novel concept such as RAMP. While we remain convinced that the gains from such an approach can out weigh the extra cost involved any comparison would need to be done using specific data for a real project. A cost framework exists to allow this but this would invariably require some modification for case specific detail.

Unfortunately at this moment in time although most of the vehicle manufacturers active in the UK have shown an interest in this approach none are currently ready to adopt such a radical approach. The project will therefore not be moving forward to looking at a real facility at this stage. It is however hoped that this will happen at some stage in the near future. It is intended to publish the findings more widely over the next 12 months with a view to attracting partners to take the concept to the next stage.



  1. Introduction


The Responsive Automotive Manufacturing Plant (RAMP) concept was developed in direct response to the perceived threats to and weaknesses of the UK Automotive Industry.
A flexible, matrix style production system was proposed that meets these requirements and allows new vehicles to be launched without disruption to current production and with minimal facility investment. The concept utilised many of the design features currently being tried by major automotive companies but was rather less conservative in the way they are applied.
RAMP is based on a matrix of cells rather than the traditional linear assembly system. It moves the body-in-white vehicles through individual process cells in which all the vehicle’s structure, system modules, core components and optional fittings are attached to achieve a specified model build. In a conventional linear system any shortages of parts, equipment breakdowns or stoppage for maintenance can force the whole line to stop, however a RAMP system will divert vehicles from a non-working cell to a working one and maintain a continuous flow of production. RAMP can also accommodate a wider range of customisation options and model variations, allowing cars to be built-to-order.
The increased flexibility inherent in the matrix assembly system also allows variations in the production volumes of each vehicle per shift. Long-term variations are accommodated by the addition of cells when required, rather than paying for all the equipment at the beginning of the project.
The RAMP system also provides increased capital utilisation and an ability to continually build new concepts or prototypes without compromising production figures.

  1. Project Deliverables

    1. 3d Simulation


A facility incorporating the RAMP method was modelled using QUEST Software; a flexible object based environment in which to build and modify discrete event simulations of manufacturing facilities. The production rates were based on forecasts produced from the SALVO project (details are shown in Table 1). A typical (though static) pictorial output is shown in Figure 1.





SWB

SWB

SWB

SWB

SWB

MWB

MWB

MWB

MWB

MWB

MWB

MWB







Cab Pick Up

Hard

top


Station Wagon

Soft Top

Chassis Cab

Hard

top


Cab Pick Up

Station Wagon

Crew Cab Pick Up

Chassis Cab

Chassis Crew Cab

Soft Top

Totals

Year 1

0

0

0

0

0

3000

27500

6000

0

500

0

0

37000

Year 2

0

500

5000

0

0

5000

36500

8000

20000

500

700

0

76200

Year 3

500

5000

9000

0

300

5000

36500

8000

20000

500

700

0

85500

Year 4

1500

9000

9000

2000

300

5000

36500

8000

20000

500

700

30

92530

Year 5

1500

9000

9000

9000

300

5000

36500

8000

20000

500

700

500

100000

Year 6

1500

9000

8150

9000

500

4000

31000

6000

32600

650

700

500

103600

Year 7

1500

9000

6500

7000

0

6000

30000

6000

19000

1000

500

0

86500

Year 8

2000

8000

3000

4000

0

7000

32800

5000

18500

500

700

0

81500

Year 9

0

0

0

0

0

8000

25000

2000

15400

500

500

0

51400

Year 10

0

200

0

0

0

1000

12200

0

9500

150

200

0

23250

Table 1. Build Prediction.




Figure 1. A Facility Utilising RAMP Technology





    1. Download 1.02 Mb.

      Share with your friends:
  1   2




The database is protected by copyright ©ininet.org 2023
send message

    Main page