Johnson Controls ensures planning through simulation
Johnson Controls is a leading global technology and industrial company offering a wide range of products and services for the building and automotive sectors. Its Power Solutions division is a leading supplier of lead-acid batteries for cars and of innovative batteries for vehicles with start-stop, hybrid and electric drive systems. Brands such as VARTA form part of the company’s product portfolio.
Initial situation: Growing demand for start-stop batteries
Demand for batteries for fuel-efficient start-stop vehicle technology was rising worldwide, prompting Johnson Controls to expand its battery assembly capacity. As part of this expansion, the pre-production process – particularly the associated logistics – was examined in detail.
Objective: To clarify oven and forklift capacity as well as AGV requirements
The focus was on two key questions:
- Is the planned number of ovens and forklifts in the pre-assembly area sufficient?
- How many vehicles from an automated guided vehicle (AGV) system are required to reliably supply and clear the assembly lines?
Solution: Simulation model with autonomous parameter adjustment
SimPlan created a simulation model that provided detailed insights into throughput, lead times, stock levels and the utilisation of ovens and vehicles, thereby validating the planning. Various scenarios were run through the model, such as furnace utilisation or the required number of vehicles. Johnson Controls was able to adjust the relevant parameters in the model independently and carry out its own simulation runs to directly examine the effects of changes.
Results: Planning validated, in-house simulation expertise developed
To support this and future planning validation, Johnson Controls had an employee trained by SimPlan in the use of the simulation software. The employee actively participated in the various phases of the study, thereby gaining first-hand experience of the approach to simulation projects. As a result, they are now able to carry out simulation studies independently in future.
Simulation builds expertise for future projects within the company
The case study demonstrates how simulation not only validates current capacity planning but also, through accompanying training, builds up long-term in-house simulation expertise within the company itself.
