Analyze Paint Line Operations to Ensure Sufficient Capacity
PACCAR designs, manufactures, and supports premium light, medium, and heavy-duty trucks under the Kenworth, Peterbilt and DAF nameplates. One of the key paint shops was operating at a slower rate than the rest of the plant. Although it appeared to have sufficient capacity within the Paint Shop to keep pace with the production rate of the trim department plant, there were human resource and materials handling issues to consider.
PACCAR wanted to solve this by synchronizing the operation with the rest of the mail assembly line. There was also an interest in optimizing the use of energy within the continuous oven to reduce production costs.
PACCAR contacted VISUAL8 to design a Paint Line Capacity Planning Simulation model to analyze the paint shop’s day to day operations. VISUAL8 developed the simulation model to:
- Identify areas to improve process flow and overall equipment effectiveness,
- Optimize the use of energy within the continuous oven to reduce production costs,
- Determine where and how large product buffers should be to handle the flow of parts,
- Examine the impact of alternative rework strategies, and
- Address how PACCAR could increase its production rate.
In determining where and how large product buffers should be to handle the flow of parts, the simulation took into account minor interruptions in supply or equipment failure or product quality. The model also reported the utilization of the Prep, Washer, Paint Booths (both robot and manual), the Flash Tunnel, the Oven and Rework Area.
The materials handling systems including the chain conveyors, manual loaders and the Storeveyor, were monitored and reported on to help identify bottleneck or starved locations.
The simulation model allowed PACCAR to examine the impact of alternative rework strategies on throughput, for example repeating Paint Shop work from scratch vs. allocating more time and resources to the touch-up area.
The Paint Line Capacity Planning Simulation model allowed PACCAR to measure the impact of an increase in parts processing on buffer and equipment loading through “what-if” analysis. Visual8 assisted PACCAR in addressing and answering the question of how to increase its production rate to the pace of the plant. The simulation model also identified how much buffer capacity was required in the system and the capability of the Paint Shop to accommodate minor interruptions in supply, equipment reliability, and to handle rework for those parts that have quality issues.