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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
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 2
Agenda
1
2
3
4
5
6
Eisenmann
Endosul Automotive Painting
Analysis of the problem
Simulation model
Results
Conclusions
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 3
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.
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 4
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
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 5
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)
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 6
1 Eisenmann – Brazil
Headquarters Eisenmann Brazil (Sao Paulo)
Manufacturing Plant (Cruzeiro)
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1 Eisenmann – Brazil
Carese – BOT Model MAN / Volkswagen
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 8
1 Eisenmann – Brazil
One paintshop for small parts
One paintshop for parts and frames
Endosul – BOT Model Randon Group
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 9
2 Endosul Automotive Painting
Final product of the costumer
Analyzed plant Paintshop for parts and frames
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 10
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
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 11
2 Endosul – Production flow
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 12
2 Endosul – Production flow
Level 0
3300
Entrance
buffer
1
2
3
4
5
6
7
8
9
10
12
11
13
7
6
5
4
3
2
1
1
2
3
2
1
5
4
3
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
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 13
2 Endosul – Production flow
Level -1
E-coat ovens
E-coat coolers
6
7
8
9
10
11
12
1
2
3
1
2
3
4
4
5
8
7
6 5
4
3
2
1
Buffers
Buffers
1 2
3
Frames preparation
Frames preparation
1
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
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 14
2 Endosul – Production flow
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 15
2 Endosul – Production flow
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 16
2 Endosul – Production flow
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 17
2 Endosul – Production flow
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 18
2 Endosul – Production flow
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 19
2 Endosul – Production flow
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 20
2 Endosul – Production flow
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 21
2 Endosul – Production flow
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 22
2 Endosul – Production flow
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 23
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
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 24
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
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 25
4 Simulation model
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 26
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
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 28
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
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 29
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
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 30
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
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 31
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
Plant Simulation Worldwide User Conference 2014 20-21/05/2014 34
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