Seeing a better future: Simulation software renders optimal plant layout before construction

MAN Nutzfahrzeuge, a heavy-duty truck manufacturer based in Munich, Germany, is substantially cutting the cost of building a new production facility by using the simulation capabilities of the DELMIA Process Engineer software package from Dassault Systemes.

12/20/2007


MAN Nutzfahrzeuge , a heavy-duty truck manufacturer based in Munich, Germany, is substantially cutting the cost of building a new production facility by using the simulation capabilities of the DELMIA Process Engineer software package from Dassault Systemes .
The new facility will produce TGA Worldwide trucks, a model specially designed to meet East European market requirements. Through 3D visualization of the building and work cell layout, DELMIA is helping MAN minimize costs and potential production problems, says MAN planner Thorsten Franz.
A truck consists of about 6,500 parts delivered in containers to the workstations. Each container of parts must be available at the right time and the right place in order to keep production flowing. The DELMIA simulation of the facility revealed how the original plans would have led to the concentration of materials at certain locations and rendered feasible work processes impossible.
MAN began by developing an initial draft plan of the new plant in Process Engineer using different assembly lines complete with line balancing on the various stations, such as framework construction, painting systems, wheel, cab and motor assembly. Then MAN used the software to configure alternative manufacturing designs, systems layouts, material handling, tests for usability, and the supply concept. Additionally, line balancing and cycle periods were all placed in context, then visualized and optimized.
"We were able to considerably minimize costs and problems through simulation. We have already achieved significant synergies among the logistics, technology and assembly divisions, we're a long way from exhausting all possibilities and will continue to review processes with DELMIA," Franz says.





Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
June 2018
2018 Lubrication Guide, Motor and maintenance management, Control system migration
May 2018
Electrical standards, robots and Lean manufacturing, and how an aluminum packaging plant is helping community growth.
April 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
June 2018
Machine learning, produced water benefits, programming cavity pumps
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
February 2018
Focus on power systems, process safety, electrical and power systems, edge computing in the oil & gas industry
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
April 2018
Implementing a DCS, stepper motors, intelligent motion control, remote monitoring of irrigation systems
February 2018
Setting internal automation standards

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
Maintenance & Safety
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me