Samples of Past Industrial Projects
The following listed are the projects that are implemented in the field
of
Production System.
Due
to privacy policy, the
exact title of the project and the clients are not mentioned. We
request
your understanding.
Crankshaft Manufacturing(2002 -
2003)
The
concept is a new
installation for flexible crankshaft manufacturing considering the
modern
production technology.
The
production capacity is
estimated to be 400,000 crankshafts per year of variable length. The
manufacturing
is divided into several cells which are connected to each other by 4
stock
segments. The
feature of this simulation
study is that it is a highly flexible Simulation model. The customer is
able to
control a multiple parameters starting from rack feed capacity, speed
of rack
speed control devices up till the breakdown value of the individual
machines. As a
feature, the client is in a position to
record the operational sequences of different crank shafts in Excel.
Thus to
achieve a simulation which was till then not flexible for the customer.
Cam shaft Manufacturing (2002)
The
simulation study is
provided for 2 stages of developments of a camshaft manufacturing. Due
to high
demand for flexibility, a temporary buffer is placed between the end of
the cam
shaft and the loops of the cam shaft. Apart from the function of the
plant, the
capacity of the temporary buffer and the ultimate waste production
disposal
were under investigation.
Further investigation the concern on determination of lot sizes for
cost reductions
are under consideration.
Parameterisation of Bottel Pack Linie
– Extension of Study 2000 (2001)
Bottel-Pack Lines 1 und 2 (1999/2000)
PKW-Assembly... (1996)
Simulation
study to
investigate assembly plant’s new concept for small PKW. As
far as possible, the
assembling is from the existing module (Cockpit, rear end (Motor,
gearbox, exhaust
pipe, rear axle), Front (front axle, headlight, bumper). The module
assembly
took place in the same location of the supplier who merged in
Just-in-time
concept. The production amounts to approx. 200,000 PKW, the round time is
1,7 min, the
turn around time is 8 hours as per the German rule. When assembling
there is no
discharge possibilities.There are 4 branches of small buffers (approx.
15 mins
work content) and they are decoupled from each other. Examined and
finished
products are arranged in 2 branches and then it is removed in a central
remachining field. The
investigation
goals were the proof function and the function availability after disturbances, the
classification of downtime
in the branches after disturbance, Module loss, Operator interference,
flaw(the
pre-buffer empty) and congestion, determination of the stock in the
temporary
buffer before the next work place, die
Ermittlung der Durchlaufzeiten und die Ermittlung der erforderlichen
Anzahl
Werker für den Nacharbeitsbereich.
Final Engine assembly ... (1995
- 1996)
Simulation
study for the investigation of an final engine assembly work including
the supply
of LKW installation (4 lines). Final engine
assembly and installation are integrated
in a Just-in-time concept. Production
amounts to approx.
900 engines for
each layer (440 mins). The Motors shall be transported into the
assembly of Electrical ly Suspended Conveyors and in the Stock-Shipping
divisions with conventional conveyor techniques (Accumulating Conveyor,
RFZ, Elevators). The
assembly takes place in 3 lines in optimized order (Line allocation of
the variants, work contents). The loading
takes place on special of transportation deck (without optional access)
in
installation sequence. Investigation
goals
were the proof of the function and the function availability with
consideration
of disturbances,
to
determine the number of expected „taxi travels“ for
the express supply of late
engines to the installation, the determination of necessary number of
EHB
vehicles, die placing and dimensioning of necessary buffers in EHB
circulation, the
organization of the remachining range for optimal throughput and the
development of tax algorithms for the cycle time regulation of
different
subranges.
Engine armament including High
time field
(1995)
Simulation
study for the investigation of a production plant to the engine final
assembly
including the supply to the installation .The final engine assembly and the installation
are integrated in Just-in-time concept. The
input is in time pulse (450 fzg/layer). The engines are developed on Subpaletten, which
are
promoted when assembling by electric suspended conveyors (EHB) and with
the
installation on assembly trolleys.
The investigation goals were the proof function and the function
availability
after disturbances,
the determination of
necessary number of EHB vehicles, Placing and dimensioning of necessary
buffers
in the EHB circulation and the development of a control algorithm for
neuralgic
points (EHB elevators, delivery of the engines of the EHBs to the
assembly
trolleys including the cancelling of empty Subpaletten of the assembly
trolleys (due
to structural reasons, only 2 assembly
trolleys and/or 4 EHB lengths) and collection of free EHBs in the
special empty
buffer.
Basics of computer integrated factory (1991 -
1994)
(Client: Volkswagen AG, Central Training/ advanced training)
Employ
Simulators SIMFLEX/2
as a control station of a model factory for the purpose of training to
co-workers of VW and to simulate the layout variants in context with
the
training course. Simulations and Control station software are identical
from
source code to the executable program (including the run time files).
SIMFLEX/2
is for the control station employment and is coupled to standard
industry
programmable controllers over Ethernet.
Sterilisation Plant (1989)
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