Factory Automation Virtual Simulation & Validation

Customer Challenge

Machine Migration Aircraft component manufacturer wanted to replace 12 old CNC M/c (Mitsubishi) to 6 high tech M/c (Makino MAG1) in order to improve process and manufacturing efficiency. Customer wanted to understand actual value benefits that can be realized and investment required for the project well before the plan is executed in real time. All new Machines to be part of flexible manufacturing cell with automated guided vehicle (AGV) for pick and place.

Scope

To develop 3D model of cell layout for new machines with robots and validate the manufacturing efficiency through virtual process simulator

Solution

As-is analysis of current conditions
Value stream mapping
Build 3D layout of cell for simulation
Virtual Factory validation
Line of Balance and Material Flow
Develop new scenarios
Plant Layout assembly and detail drawing
Business case of value benefits

Features

Design and develop new production scenarios
Line of Balance & Precedence charts
Redefine Process plans & fixtures
NC programs with online inspection
Tools Used : Catia, Tecnomatix, 3DVIA

Benefits

Decrease throughput time as much as 40-60%
Increase production efficiency by 25-to 40%
Optimized factory space by 45% & allowed space for new capital equipment’s
AGV & Green Button concept reduced manual intervention and idle time by 60%
Standardised Tooling’s & Fixtures – Zero investment to accommodate new commodities
Operator per shift reduce from 12 to 3