Modeling and Optimization of the Production and Logistic Concept of the Siemens "Factory One" in Zug

Abstract: This thesis is part of a study to prove the feasibility of the logistics and production concept of a new production plant built by the business unit Building Infrastructure of the multicorporate enterprise Siemens in Zug, Switzerland. In order to perform this analysis the model of the factory built in the discrete-event simulation tool “Tecnomatix Plant Simulation” is used. Prior student works aimed at answering the question whether the internal logistics should be performed by a milkrun or a flexible transportation system (FTS). They proved that the FTS is more robust. However, their work did not fully prove the feasibility of the logistics concept and left two key questions unanswered. First, based on the high utilization of the FTS in the simulation the concern was raised whether the FTS could be the bottleneck of the system. Second, Siemens reduced the logistics area for the incoming and outgoing goods considerably and it needs to be determined whether the logistics area is large enough. To answer the first question a new demand oriented control for the FTS is developed and several load scenarios are applied. The new control proves that the FTS is not the bottleneck of the system and can channel substantially more material through the system than anticipated in the production forecast. The sensitivity analysis has also shown that the FTS can operate at considerably lower speeds that expected. In order to determine the space requirements for the logistics area all processes and material flows for this area are identified and implemented into the model. Based on the load scenarios and additional information it is determined that the provided area is too small. Furthermore, the simulation showed that the processes are sensitive to changes. Therefore, Siemens decided in a workshop based on the simulation to enlarge the area to provide additional capacity. Finally, it was decided to increase the area by 50%. By answering these two questions this thesis finalizes the feasibility analysis of the logistics concept. Furthermore, this work lays the foundation for analyzing the feasibility of the production concept by providing a detailed investigation into the new production concept of Siemens and by proposing a model for the production cells which complements the logistics simulation.