Product category:
Simulation, modelling and validation software
News Release from: Delmia | Subject: Quest discrete event simulation package
Edited by the Engineeringtalk Editorial
Team on 06 November 2001
Simulation improves manufacturing cell
performance
A combination of modelling a manufacturing cell in Delmia's Quest and applying lean manufacturing techniques recently helped N and R Engineering improve the cell's performance
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
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.
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.".
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