Paint Shop Construction: Simulation Supports Projects from Planning Through Commissioning
Software: Plant Simulation
b+m surface systems GmbH builds paint shops and automated application systems for virtually any painting task. This medium-sized, internationally active company primarily serves the automotive and supplier industries. Manufacturers of commercial vehicles, agricultural machinery, and rail vehicles also use b+m systems for painting.
Initial Situation: Increasing Complexity and Time Pressure
Customers’ processes are becoming more complex, while project timelines are shrinking. As a result, b+m decided to invest in the digital factory. The goal: higher-quality planning and lower follow-up costs.
Objective: Simulation Across the Entire Value Chain
Together with SimPlan, b+m evaluated and implemented the Plant Simulation program. The goal was to gradually apply event-driven simulation across the entire value chain: from the initial planning steps through detailed planning and commissioning to advising the end customer during ongoing operations.
Solution: Material flow simulation from preliminary planning to stress testing
At the start of the collaboration, material flow simulation supported the early planning phases of a paint shop for passenger car components. To this end, b+m modeled the current state of planning and thus identified weak points at an early stage. The team adjusted the layout accordingly.
Plant Simulation also offers a wide range of options for animating material flow. This provided b+m with an effective tool for presenting and discussing different solution options with the customer.
As the project progressed, b+m and SimPlan gradually refined the model. Based on the current state of planning, they conducted several stress tests. The model also took into account the acceleration and deceleration behavior of the conveyor system, as this was the only way to realistically test different control options. This resulted in an accurate picture of the future reality, including fluctuations and disruptions.
The insights gained formed the basis for the actual control logic in the model. They also supported the commissioning of the system.
Results: Higher Planning Quality Through Early Simulation
Using Plant Simulation, b+m validates customer projects through simulation as early as the design phase. Sebastian Merz, managing partner of b+m surface systems GmbH, sums it up as follows: “With Plant Simulation, we can validate customer projects through simulation as early as the planning phase and thus ensure higher planning quality.” He adds: “SimPlan supported us with advice and assistance right from the start. During the implementation of Plant Simulation, our employees were trained on an ongoing basis throughout the project using actual orders, enabling them to quickly familiarize themselves with the new program in a practical way.”
The Digital Factory as a Path to Greater Planning Reliability
Simulation pays off not only for an individual project but for the entire value chain. After all, the earlier a company identifies weaknesses in the layout, the more cost-effectively adjustments can be implemented. b+m demonstrates how simulation grows step by step across multiple project phases: from preliminary planning through detailed planning to commissioning. In this way, it becomes an integral part of project work rather than a one-time additional service.
