FLOW SIMULATION OF AN OUTPUT SHAFT LINE: Capacity analysis and optimization of the overall process efficiency
Abstract: Scania CV AB is a world leading provider of sustainable transport solutions. This includes trucks and buses, as well as an extensive offering of product-related services. This project takes place at the Södertälje plant and is carried out under the Transmissions Manufacturing department, with the output shaft line as the main focus. Due to a higher scale of product demand, the department aims to extend the line's production capacity to include both additional components and a higher production volume. The line under investigation consists of eleven serial processes. The project sets out to investigate the line's dynamic, find a theoretical maximum capacity for different product types and derive a reasonable OPE goal. Moreover, the project's final objective refers to how un-utilized capacity can be revealed. The project's results are delivered in three distinct parts. Firstly, a complex and thorough simulation model is delivered to the department alongside usage instructions. The model in its entirety is found in appendix A3. It is crucial to ensure that the model describes the real system. Therefore, the second result is an extensive model verification and validation. Lastly, results to where un-utilized capacity can be found is presented. General findings are that, reducing the cycle times to the times stated in the buy-in contract alongside with reducing the length (but not frequency) of shutdowns gives a considerable capacity enhancement. All further optimization endeavours assumes that the line's cycle times have already been reduced to the purchased times. Moreover, it is possible to increase product type one's manufacturing capacity by 11,4%, product type two's capacity by 13,1% and product types three and four's capacity with 7,2%. The capacity enhancements depends on several parameters for the different product types.
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