Automotive supplier: Ensuring system performance in gearbox assembly
Initial situation: Focus on mechanical manufacturing with gantry control
An automotive supplier specialising in mechanical manufacturing and gearbox assembly wanted to have the machining of gearboxes analysed using simulation before deciding on the final system design.
Objective: Identifying bottlenecks, correctly sizing workpiece carriers
The aim was to ensure system performance, identify potential bottlenecks, determine the required number of workpiece carriers and compare different gantry control variants.
Solution: Simulation using the Powertrain module in Plant Simulation
SimPlan used Plant Simulation with the Powertrain module for the simulation. The model provided a detailed representation of the gantry control and movement, as well as the loading and unloading processes in the workpiece carrier cycle and the workpiece changeover processes during mechanical machining.
Results: Bottleneck operations identified, influence of workpiece carriers quantified
The simulation identified the bottleneck operations within the system and ensured the planned output. Furthermore, it was possible to quantify the extent to which the number of workpiece carriers influences system performance – a key factor in deciding on the gantry control variant.
Simulation as a basis for decision-making in plant design
The case study demonstrates how a detailed simulation of the gantry control system and the workpiece carrier cycle can be used to identify both bottlenecks and the correct sizing of equipment prior to implementation.
