CASE STUDY

A new engine programme includes the preparation of a Work Standard and a scaled physical Layout Drawing. A Work Standard is a list of all the assembly operations that have to be performed to produce a finished engine, with each of the operations taking place at a different position along the assembly line. The Layout Drawing shows the physical position of these operations and the conveyoring required to link them together. For simulation purposes, the Work Standard and Layout Drawing data are consolidated into a Microsoft Excel spreadsheet along with other information such as reliability and maintenance data, shift patterns and local control logic. When the data has all been entered the Excel application automatically generates the finished model. A series of core WITNESS elements has been pre-defined to cover all the commonly used types of equipment found on an engine assembly line, e.g. automatic and manual operations plus line automation such as conveyors, divert stations and turntables. Positioning information ensures that each piece of equipment is displayed in the correct orientation and is correctly aligned relative to the preceding piece of equipment. Several functions within WITNESS automatically populate and link the elements together seamlessly to create a fully functional model without any further user intervention. This approach has significantly reduced the time it takes to build a model. The main effort is now concentrated on amalgamating the Layout dimensions and Reliability data into a modified version of the Work Standard. Making adjustments to an existing model becomes trivial, requiring only the relevant part of the Simulation Work Standard to be updated. The reduction in model building and modification time has meant that more detailed programmes of investigation can be considered, with the results being available whilst those issues under consideration remain current. Additional benefits include a consistent “look and feel” to these models, a reduction in validation testing due to the re-use of proven logic, and the opportunity for non-expert users to confidently build and use models. Ford are now looking to expand the use of this technology across a range of other areas, including the machining lines that produce items such as cylinder heads, engine blocks and crankshafts. Ford see the FAST tool as a significant step forward in their continued drive to roll out powerful analytical technologies to the workplace.

Lanner helps organisations achieve rapid and effective business change. Based in the UK with subsidiaries and partners in Europe, the Americas and the Far East, Lanner works with more than 3000 top multi-national companies.

www.lanner.com