ANALYSIS OF A PAINTING FACILITY FOR TRUCK FRAMES...

Plant Simulation Worldwide User Conference 2014 20-21/05/2014

www.eisenmann.com

© Eisenmann AG 2014

ANALYSIS OF A PAINTING FACILITY FOR TRUCK

FRAMES USING PLANT SIMULATION

Tiago Vacaro, Eisenmann Brazil

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Agenda

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Eisenmann

Endosul Automotive Painting

Analysis of the problem

Simulation model

Results

Conclusions

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1 Eisenmann

Eisenmann is a leading global provider of industrial solutions and services for

surface finishing, material flow automation, thermal process technology and

environmental engineering.

Headquarters in Germany, at the cities of Böblingen and Holzgerlingen.

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1 Eisenmann – Products and Services

AUTOMOTIVE SYSTEMS

Surface finishing, body shell conveyor systems, final assembly lines

GENERAL FINISHING

Paint shops for metal parts, paint shops for plastic parts, paint shops for wooden parts, new materials

Pretreatment and coating systems, high-temperature technology, firing lines for ceramics, heat treatment, carbon

fiber ovens

PROCESS & HIGH TEMPERATURE TECHNOLOGY

CONVEYOR SYSTEMS

Electrified monorail systems, inverted electrified conveyors, Power & Free conveyors, peripheral conveyor

systems

SERVICE

Customer service, spare parts management, plant renewal, advisory services, full-service & BOT models

ENVIRONMENTAL TECHNOLOGY

Exhaust air purification, waste water treatment, waste disposal, ammunition disposal, biogas plants

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1 Eisenmann – Locations

Paris Crystal Lake

Sao Paulo

Fuzhou

Kunshan

Shanghai

Cruzeiro Chennai

Delhi Thane

Country with Eisenmann location

Country with Eisenmann sales

representatives

Changchun

Puebla

Pune

Moscow

Saronno

Göttingen (Ruhstrat)

Böblingen

Holzgerlingen

Erftstadt (intec)

Stafford

Barcelona

Resende

Caxias do Sul

BOT Models (Build, Operate and Transfer)

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1 Eisenmann – Brazil

Headquarters Eisenmann Brazil (Sao Paulo)

Manufacturing Plant (Cruzeiro)

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1 Eisenmann – Brazil

Carese – BOT Model MAN / Volkswagen

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1 Eisenmann – Brazil

One paintshop for small parts

One paintshop for parts and frames

Endosul – BOT Model Randon Group

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2 Endosul Automotive Painting

Final product of the costumer

Analyzed plant Paintshop for parts and frames

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Conveying by

automatic hoists and

transfer bridges

2 Endosul – Production flow

Entrance buffer

Loading

Shotblasting

Pre-treatment

Rotate machine –

cleaning and

rotation

E-coat painting

Curing

oven

Liquid

Top-coat

painting

Powder

Oven Oven

Unloading – delivery

of the frame to the

costumer

Preparation for

top-coat painting

Cooler

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2 Endosul – Production flow

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2 Endosul – Production flow

Level 0

3300

Entrance

buffer

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5

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Top-coat ovens

Top-coat coolers

Buffers Buffers

Top-coat audit 2

1

Liquid painting

Loading of frames

Blasting cleaning

Return of empty load bars

Shotblasting

Rotate machine

Transfer bridge

Powder painting

Unloading of frames

Lift

Transfer bridge Lift

Transfer bridge

Transfer bridge

Transfer bridge

Transfer bridge

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2 Endosul – Production flow

Level -1

E-coat ovens

E-coat coolers

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Buffers

Buffers

1 2

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Frames preparation

Frames preparation

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2

Unloading of parts

UF Cleaning

Return of empty load bars

Shotblasting Blasting cleaning Loading of parts

Pre-treatment tanks

Transfer bridge

Transfer bridge

Hoist

Hoist

Hoist

Transfer bridge

Lift

Lift

Entrance at tanks for bars with parts

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2 Endosul – Production flow

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2 Endosul – Production flow

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2 Endosul – Production flow

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2 Endosul – Production flow

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2 Endosul – Production flow

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2 Endosul – Production flow

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2 Endosul – Production flow

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2 Endosul – Production flow

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2 Endosul – Production flow

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Demand

scenarios

Demand

(Frames)

Capacity

(Frames) Utilization (%)

Available

capacity (%)

Current 70 110 64 +36

Future 130 110 118 -18

How the computer simulation could help in the

decision making of modifications of the production

process

3 Analysis of the problem

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3 Analysis of the problem

Change Description Investment

(millions of €)

1 Increase of the speed of the powder painting line 0.33

2 Reduction of processing times of the tanks for surface pre-treatment and

e-coat painting 0.33

3 Reduction of the processing times of ovens and coolers 0.03

4 One additional hoist at the tanks area (with five variants regarding the

configuration of the hoists) 0.50

5.1 A second workstation at the exit of the tanks area (Cleaning UF) 0.50

5.2 A second workstation at the exit of the tanks area + the replacement of

one e-coat oven by a cooler 0.33

6 Replacement of two e-coat ovens by coolers 0.33

7 One additional transfer bridge for the area of e-coat ovens and coolers 0.33

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4 Simulation model

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5 Results

Dozens of indicators :

times of workstations;

occupation of ovens, coolers and buffers;

indicators for the tanks area;

general process indicators :

throughput

work in process

mix frames/parts

cycle time Main indicator set for the comparison of

results average cycle time of frames

Plant Simulation Worldwide User Conference 2014 20-21/05/2014 27

Data: 15/03/2013 Tempo de simulação: 100 dias (24 horas por dia)

Mix

Modelo

Tempo de

atravessamento

nos tanques

Ocupação

média dos

tanques

Tempo de ciclo

médio limpeza

UF

Ocupação

média estufas e-

coat

Tempo médio

estufas e-coat

Ocupação

média

resfriadores

e-coat

Tempo médio

resfriadores

e-coat

WIP médio de

chassis

WIP médio de

jobs de peças

Quantidade de

chassis

processados

Quantidade de

jobs de peças

processados

Tempo de ciclo

de chassis

Tempo de ciclo

de peças

Taxa de

produção de

chassis

Taxa de

produção de

peças

Taxa de

produção total

Mix

chassis/peças

15.03.13_PEC_Present_status 0:57:31 6,08 0:07:13 10,17 1:23:18 3,81 0:31:13 32,35 10,61 11662 5877 0:12:19.63 0:24:28.10 4,859 2,449 7,308 1,984

15.03.13_PEC_Change_1 0:57:29 6,07 0:07:12 9,94 1:21:24 3,81 0:31:13 32,23 10,54 11675 5878 0:12:18.87 0:24:27.74 4,865 2,449 7,314 1,986

15.03.13_PEC_Change_2 0:57:30 6,08 0:07:12 10,34 1:24:42 3,81 0:31:13 32,35 10,68 11671 5878 0:12:18.97 0:24:27.70 4,863 2,449 7,312 1,985

15.03.13_PEC_Change_3 0:57:50 6,09 0:07:15 5,80 0:47:44 3,62 0:29:47 30,62 9,24 11596 5880 0:12:23.92 0:24:27.59 4,832 2,450 7,282 1,972

15.03.13_PEC_Change_4.1 0:58:56 6,25 0:07:12 10,20 1:23:29 3,81 0:31:13 32,37 10,68 11673 5879 0:12:18.95 0:24:27.70 4,864 2,449 7,313 1,985

15.03.13_PEC_Change_4.2 0:57:34 6,09 0:06:57 11,22 1:31:49 3,81 0:31:12 32,50 10,96 11689 5879 0:12:17.95 0:24:27.63 4,870 2,450 7,320 1,988

15.03.13_PEC_Change_4.3 0:52:42 5,33 0:07:08 6,56 0:55:22 3,74 0:31:35 30,59 9,39 11160 5881 0:12:52.86 0:24:27.05 4,650 2,450 7,100 1,898

15.03.13_PEC_Change_5.1 0:54:46 5,70 0:07:11 9,59 1:19:11 3,80 0:31:21 32,33 10,76 11566 5850 0:12:25.77 0:24:34.77 4,819 2,438 7,257 1,977

15.03.13_PEC_Change_5.2 0:39:09 4,19 0:03:38 6,75 0:50:30 4,30 0:32:09 31,86 8,58 13327 5882 0:10:47.31 0:24:26.98 5,553 2,451 8,004 2,266

15.03.13_PEC_Change_6 0:55:58 6,01 0:07:03 6,17 0:49:31 4,10 0:32:53 31,11 9,41 12032 5882 0:11:56.94 0:24:27.02 5,013 2,451 7,464 2,045

Mudança 1: Linha pintura pó (chassis) mais rápida Mudança 5: Uma segunda estação de trabalho na saída dos tanques (limpeza UF)

Mudança 2: Redução de tempos de processo nos tanques 5.1: Somente inclusão da segunda estação de trabalho

Mudança 3: Redução de tempos de processo de estufas e resfriadores 5.2: Inclusão da segunda estação, mais substituição de uma estufa e-coat por um resfriador

Mudança 4: Uma quarta TTB (ponte rolante) no pré-tratamento Mudança 6: Duas estufas e-coat substituídas por resfriadores

4.1: Primeira distribuição de pontes

4.2: Primeira distribuição de pontes mais redução do tempo de processo na estação ST4

4.3: Segunda distribuição de pontes

ThroughputTanques Ocupação estufas e resfriadores e-coat WIP Quantidades processadas Tempo de ciclo

5 Results

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Model Average cycle time

[min:s.ss]

Investment

(millions of €) Model

Average cycle

time [min:s.ss]

Investment

(millions of €)

Current_status 12:18.78 0.00 Changes_3+5.1 0:11:00.98 0.20

Change_1 12:20.51 0.33 Changes_3+4.5+5.1 0:11:01.52 0.70

Change_2 12:20.06 0.33 Changes_2+3+5.1 0:11:01.91 0.53

Change_3 12:25.60 0.03 Changes_2+3+4.5+5.1 0:11:02.97 1.03

Change_4.1 12:21.00 0.50 Changes_1+2+3+5.1 0:11:01.28 0.87

Change_4.2 12:22.06 0.50 Changes_1+2+3+4.5+5.1 0:11:03.35 1.37

Change_4.4 12:20.03 0.50

Change_4.5 12:19.27 0.50 Changes_4.5+5.2 0:11:00.11 0.83

Change_5.1 12:27.28 0.17 Changes_3+4.5+5.2 0:11:00.14 0.87

Changes_1+3 12:24.44 0.37

Changes_2+3 12:25.19 0.37 Change_5.2 0:10:47.17 0.33

Changes_1+2+3 12:24.78 0.70 Changes_3+5.2 0:10:47.29 0.37

Changes_2+4.5 12:19.29 0.83

Changes_2+5.1 12:21.41 0.50 Changes_2+5.2 0:10:24.52 0.67

Changes_4.5+5.1 12:25.68 0.67 Changes_2+4.5+5.2 0:10:24.57 1.17

Changes_2+4.5+5.1 12:27.64 1.00 Changes_2+3+5.2 0:10:24.14 0.70

Changes_2+3+4.5+5.2 0:10:24.60 1.20

Change_4.3 12:52.89 0.50 Changes_1+2+3+5.2 0:10:24.81 1.03

Changes_1+2+3+4.5+5.2 0:10:24.59 1.53

Change_6 11:56.82 0.33 Changes_1+2+3+4.5+5.2+7 0:10:28.45 1.87

5 Results

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10:00.0

10:15.0

10:30.0

10:45.0

11:00.0

11:15.0

11:30.0

11:45.0

12:00.0

12:15.0

12:30.0

12:45.0

13:00.0

13:15.0

Ave

rag

e c

yc

le t

ime

of

fra

me

s [

min

:s.s

s]

Current status and changes

applied separately

5 Results

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10:00.0

10:15.0

10:30.0

10:45.0

11:00.0

11:15.0

11:30.0

11:45.0

12:00.0

12:15.0

12:30.0

12:45.0

13:00.0

13:15.0

Ave

rag

e c

yc

le t

ime

of

fra

me

s [

min

:s.s

s]

Reduction of processing times of

ovens and coolers, and inclusion

of a second workstation for UF

cleaning

5 Results

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10:00.0

10:15.0

10:30.0

10:45.0

11:00.0

11:15.0

11:30.0

11:45.0

12:00.0

12:15.0

12:30.0

12:45.0

13:00.0

13:15.0

Ave

rag

e c

yc

le t

ime

of

fra

me

s [

min

:s.s

s]

Inclusion of a second workstation for

UF cleaning, and the substitution of

one e-coat oven by a cooler

5 Results

Plant Simulation Worldwide User Conference 2014 20-21/05/2014 32

10:00.0

10:15.0

10:30.0

10:45.0

11:00.0

11:15.0

11:30.0

11:45.0

12:00.0

12:15.0

12:30.0

12:45.0

13:00.0

13:15.0

Ave

rag

e c

yc

le t

ime

of

fra

me

s [

min

:s.s

s]

Inclusion of a second workstation for UF cleaning, the

substitution of one e-coat oven by a cooler, and the

reduction of processing times on the tanks for surface

pre-treatment and e-coat painting

5 Results

Plant Simulation Worldwide User Conference 2014 20-21/05/2014 33

Model Description Cycle time

reduction

Increase of

throughput

Investment

(millions of €)

Changes_3+5.1

reduction of processing times of ovens and

coolers, and inclusion of a second workstation for

UF cleaning

78 s 12% 0.20

Changes_5.2

inclusion of a second workstation for UF cleaning,

and the substitution of one e-coat oven by a cooler 91 s 14% 0.33

Changes_2+5.2

inclusion of a second workstation for UF cleaning,

the substitution of one e-coat oven by a cooler, and

the reduction of processing times on the tanks for

surface pre-treatment and e-coat painting

114 s 18% 0.67

5 Results

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Proposal Changes Investment

(millions of €) Increase of

capacity

Before simulation Changes_1+2+3+4.5+5.2+7 1.87 18%

After simulation Changes_2+5.2 0.67 18%

Investment saving 1.2

5 Results

Plant Simulation Worldwide User Conference 2014 20-21/05/2014 35

The changes could be analyzed separately and in combination,

giving security for the decision making;

Saving of 64% on the resources to be applied to obtain the

necessary increase of capacity;

In monetary values, reduction of the necessary investment from

1.87 to 0.67 Million of Euros;

Increase of capacity in 18% with only 2 modifications, against 6

initially defined.

6 Conclusions

Plant Simulation Worldwide User Conference 2014 20-21/05/2014

www.eisenmann.com

© Eisenmann AG 2014

Thank you!

TIAGO VACARO

tiago.vacaro@endosul-pa.com.br