Simulation as a Manufacturing Process Planning Tool

Currently there is a heavy reliance on computer tools for part design in the Indian automobile industry. But when a part goes past the design approval stage to planning of the manufacturing process, there is a tendency to rely on personnel expertise and past experiences in the design of the manufacturing system. Modifications made to a manufacturing process at a later stage can prove to be costly and time-consuming. Key factors to remain competitive in the manufacturing business are the effective and efficient operation of installed manufacturing systems, as well as the ability to quickly and readily reconfigure these systems in the case of product line modifications. This paper looks at the usage of simulation tools to aid process planners in decision-making and presents some of the advantages offered by its usage prior to taking the manufacturing process online.

Digital Manufacturing is becoming an indispensable tool in streamlining the design to implementation process. A case study of a discrete event simulation model of an engine test cell from conceptual designs and proposed processes is discussed. The purpose is to evaluate capacity output requirements from the line and for visualization of material handling equipment. This model is simulated in real time mode to study the feasibility of the process. Both the advantages and disadvantages of using simulation modeling during the planning process are analyzed.