Simulation as a basis for decision-making in paint shop planning: How many body skids does your facility really need?
When planning a paint shop, one of the most difficult questions to answer is: How many body skids – also known as ‘skids’ in technical terminology – and overhead conveyor hangers are actually required to ensure that storage, conveyor systems and rework operate seamlessly together? Too few will slow down the production cycle. Too many will tie up capital and clog up the storage areas. This real-world case study from the automotive industry demonstrates why this question cannot be answered using a static calculation.
Initial situation: New layout following refurbishment and expansion
A leading German car manufacturer was planning the expansion and refurbishment of its paint shop. Following the structural alterations, the new layout had to be mapped out and the allocation across the various storage areas reassessed. Before the facility went into regular operation, the project managers were faced with key questions: Will the new layout maintain the planned throughput? How many body carriers are actually required? And how do rework rates affect the material flow?
Three challenges that a static calculation cannot resolve
1. Storage with multiple areas: A paint shop consists of several storage areas that must be coordinated with one another. An incorrect allocation of capacity slows down the entire material flow, often without the cause being apparent at first glance.
2. The interaction between body carriers and EHB: Two different conveyor systems must synchronise their cycles. If you consider them separately, you overlook the interactions that determine the actual throughput.
3. Fluctuating rework rates: Rework alters the material flow in unpredictable ways. Only a dynamic analysis over time reveals the extent to which rework rates actually affect bottlenecks and throughput.
The simulation approach: the interaction of all systems in detail
Using Plant Simulation and the Automotive Module Library, the complex storage control of the paint shop was modelled in detail, as were the body carrier and EHB cycles. The model took into account varying rework rates and their effects on material flow. The results were analysed in SimAssist.
Instead of relying on a single assumption, various operating modes and storage strategies were simulated. This made it possible to identify where bottlenecks arise and how many body carriers are required for stable operation.
Results: Planning certainty for the new paint shop
- Bottlenecks were identified and could be eliminated in good time.
- The planned increases in throughput were confirmed.
- The required number of body carriers was determined.
- Potential for optimising the operating modes was identified.
- The simulation model will continue to be used for future studies.
The overarching lesson: Paint shop planning requires dynamic methods
This case study illustrates a pattern that recurs in many paint shop simulation projects. For a commercial vehicle manufacturer, the aim was to identify bottlenecks and evaluate a planned storage expansion, including an operator model to assess different body lengths and colours. In another expansion project, the focus was on adding an additional line to an existing paint shop, working to a tight schedule due to long lead times for EHB hangers.
Whether it’s a new build, a refurbishment or an expansion: simulation projects at SimPlan consistently raise the same questions.
- How many body carriers and EHB hangers are actually needed?
- How do the production mix and rework affect the material flow?
- Will storage capacity remain sufficient even after an expansion?
Those who only answer these questions after commissioning end up paying the price, for example through losses in throughput or subsequent adjustments to conveyor systems and storage concepts. Simulation, on the other hand, provides a robust basis for decision-making right from the planning phase.
Are you planning a paint shop project?
Are you planning the refurbishment or expansion of a paint shop, or do you want to determine the appropriate number of body carriers and EHB hangers? We can support you with simulation studies to validate storage concepts, conveyor systems and throughput.
You can find further case studies, technical articles and practical examples on the SimPlan blog and in the SimPlan podcast.
