Simulation and optimisation of a manufacturing process : A case study of a high mix and low volume manufacturing process at Atlas Copco

Abstract: Companies are constantly seeking new ways to increase their efficiency and flexibility to be able to meet the market demand, industry 4.0 has provided companies with new tools that enables them to better track the performance of a process and more easily optimise it. In a high mix and low volume manufacturing process a lot of inefficiencies are prone to occur due to the high variety. A simulation can be a very beneficial tool to use in the optimisation of a manufacturing process. In a simulation a digital twin of the physical process is constructed to replicate the real-world results, the simulation can then be used to test how changes to the process affects the desired performance objectives. The purpose of this study was to use a simulation to optimise the process by increasing output and reduce lead time as well as increase the visual presentation of the process. The purpose was fulfilled by a review of literature on the subject, interviews, observations and a document study before a simulation model and value stream map was constructed. The bottleneck analysis and the value stream map highlighted a few inefficiencies in the process that was solved by implementing a few solutions that would improve the balance of the process and increase output and decrease lead time. A visual presentation tool was also developed to calculate the expected lead time for a new order and show how the flow of orders would develop in the near future.