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Author:Saarentaus, Otso
Title:Simulation and Modelling of Mixed Model Order-To-Delivery Automotive Manufacturing
Tilauspohjaisen, sekatuotantoon perustuvan autotuotannon simulointi ja mallinnus
Publication type:Master's thesis
Publication year:2014
Pages:x + 88      Language:   eng
Department/School:Sähkötekniikan korkeakoulu
Main subject:Älykkäät tuotteet   (ETA3006)
Supervisor:Kyrki, Ville
Instructor:Wetterstrand, Tommi
Electronic version URL: http://urn.fi/URN:NBN:fi:aalto-201405131810
OEVS:
Electronic archive copy is available via Aalto Thesis Database.
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Location:P1 Ark Aalto  1048   | Archive
Keywords:automotive
simulation
modelling
SIMUL8
mixed model production
mixed vehicle production
auto
tuotanto
simulointi
mallinnus
sekatuotanto
autotuotanto
ajoneuvotuotanto
Abstract (eng):Automotive manufacturing usually consists of complicated manufacturing processes with up to thousands automotive parts involved.
The product is heavy which requires heavy conveyors.
Therefore changing the manufacturing methods can require large investments.
Simulation of the process is preferred before making physical changes to the line.
The aim of this Master's thesis is to verify the capabilities of an automotive paintshop department by creating a simulation model for it.
The basics of production engineering, automotive production principles, simulation and modelling are studied to support the case.
In the review of automotive production systems the focus is on mixed model sequencing.
To create a reliable model the theory behind simulation is studied from two different aspects: simulation project principles and simulation modelling theory.
Simulation software SIMUL8 Basic was chosen for the simulation and verified to fulfill the requirements for an automotive simulation study.
The simulation model was built from data gathered from the facility.
The data was verified by the production engineers.
Two experiments were made with the simulation model.
First production with two shifts was tested.
After that mixed model production with three different products was tested.
From the simulation experiments, it was noticed that by managing production speeds in the beginning of the paintshop process we can maintain a better production balance for the department.
To manage problems caused by mixed model production, it was noticed that the batching functionality placed before the top coat painting section was of high relevance and should be studied further.
The simulation program SIMUL8 Basic worked well in the simulations.
However, to program advanced functionality into the model, an updated version, SIMUL8 Pro, would be required.
Abstract (fin):Autotuotanto sisältää monimutkaisia prosessivaiheita ja tuhansia ajoneuvon osia.
Tuotettava tuote on raskas ja vaatii suuria siirtokuljettimia, minkä takia muutokset tuotantolinjaan voivat vaatia suuria investointeja.
Tästä johtuen on suositeltavaa simuloida tuotantoprosessi ennen fyysisten muutosten tekemistä.
Tämän diplomityön tavoite on selvittää autotehtaan maalaamo-osaston ominaisuuksia simuloinnin avulla.
Selvityksen tueksi tutustutaan tuotantotekniikkaan, autotuotannon toimintaperiaatteisiin, simulointiin ja mallinnukseen.
Autotuotannon toimintaperiaatteissa keskitytään pääosin sekatuotantomenetelmiin ja tuotteiden jonotukseen tuotannossa.
Simuloinnin teoriaa tarkastellaan kahdesta näkökulmasta luotettavan simulointimallin tueksi: simulointiprojektin periaatteet ja mallinnuksen teoria.
Simulointiohjelmistoista SIMUL8 Basic valittiin käytettäväksi työssä.
Valitun ohjelman ominaisuudet kokeiltiin erikseen ja todennettiin, että ohjelma sopii ajoneuvotehtaan simulointiin.
Simulointimalli rakennettiin tehtaalta kerätyn tiedon pohjalta.
Tuotannonsuunnittelijat arvioivat ja hyväksyivät simulointimallin ennen kuin mallilla tehtiin simulointikokeita.
Mallilla tehtiin kaksi simulointikoetta.
Ensin kokeiltiin tuotantoa kahdella vuorolla, minkä jälkeen tehtiin koe sekatuotannosta kolmella eri tuotteella.
Simulointikokeista huomattiin, että jos tuotantotahtia maalaamon alussa hallittaisiin tarkemmin, voitaisiin pitää tuotanto tasaisempana.
Sekatuotantoa simuloitaessa huomattiin, että autojen pakkaaminen eriksi ennen pintamaalausta tulisi tehdä erityisen tarkasti ja sitä kannattaa tutkia lisää.
Valittu simulointiohjelma toimi hyvin simuloinneissa, mutta monimutkaisten toimintojen simuloimiseksi tulisi ohjelma päivittää SIMUL8 Pro versioon.
ED:2014-05-18
INSSI record number: 49042
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