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Furthermore, to truly capture the nature of an assembly line, it is necessary to consider the dynamic nature of transporter vehicle speeds, traffic conditions, access to shared resources, and stochastic demand. Traditional analysis techniques based on spreadsheets cannot consider the complexities of a modern automotive assembly line, such as the processes involved and the relationships between them. Assembly line policies – quality, numbers at line, ‘one touch – one motion’, etc.Time and space constraints – shared pathways and time critical activities.Complex transportation – including forklifts and car-set delivering AGVs.Component variability – the van’s wing mirror has 130 variants.Numerous components – tens of thousands of part numbers assembled in the same plant.While considering the efficiency and optimization of the aspects listed above, planning engineers had to ensure they met the challenges of the commercial van production line: Time lost (due to traffic, waiting, repacking, etc.)Ībove all, for profitability, there should be no production stoppages caused by assembly line shortages.Workforce pooling (especially for irregular tasks).The company’s logistics engineers needed a tool to assess and optimize the efficiency of automotive plant intralogistics in the context of a large-scale AGV implementation. Problem: Assembly line optimization and efficiency
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The first stage of the project realized an efficiency gain of 5% and identified further significant gains for the next stage. With over 3.4 million deliveries of the commercial vehicle from various production sites, the company wanted an optimization tool with the flexibility to apply at different plants and account for technologies such as autonomous guided vehicles (AGV). Engineers at a world-renowned German automotive manufacturer sought a modern and optimized production line for the company’s highly successful commercial van.