Analyze Space Requirements for Supply and Product Flows
Magna International is globally the most diversified automotive supplier that designs, develops and manufactures automotive systems, assemblies, modules and components, and engineer and assembles complete vehicles to original equipment manufacturers (OEMs). The Cam-Slide of the Magna Intier Division produces seat-track slides for a diverse group of customers at its plant in Aurora, Ontario.
With the growth in business, Cam-Slide’s Management team required a Plant Simulation of its Cam-Slide Plant operations to determine the floor space requirements of their shipping and receiving area and materials holding area based upon current and future production of volumes.
The project would be developed in two phases:
- Shipping and receiving simulation, and
- Work-in process simulation.
Visual8 worked closely with members of Cam-Slide’s management team and developed a Plant Workflow Simulation of the Cam-Slide plant operations, which was completed in two phases. All relevant plant operations and process options were properly defined and captured.
In the first phase, Visual8 developed an initial working simulation model of production and its demands on material inflows and outflows to the plant. The model utilized current plant operational data, combined with shipping schedules, to provide an accurate estimate of the space requirements placed on the shipping and receiving areas. Input parameters included information regarding:
- Assembly lines,
- Forklift operations,
- Resource shift patterns,
- Warehousing, and
- Shipping and receiving.
- Product production,
- Material flow within the plant,
- Capacity issues, and
- Order fulfillment.
The second phase allowed Visual8 to model plant operations in further detail and to investigate the effects of sub-assembly storage on assembly operations. Input parameters included information regarding:
- The bill of materials for each product,
- Supply bin dimensions, and
- Batch sizes, supply arrival schedules, and processing times for individual machines within each production line.
Detailed output results included: supply availability, material flow within the plant, and capacity issues.
The Cam-Slide Plant Workflow Simulation tool provided the management team the ability to analyze space requirements throughout the plant as well as analyze supply and product flows. This resulted in a more accurate capacity planning estimate to meet the growth in business.