A leading manufacturer of plastic serial and original car styling accessories for both internal and external passenger car applications faced a critical bottleneck in the foaming division of their production line. This major Austrian automotive supplier turned to AnyLogic Simulation and Modeling software to explore solutions without disrupting current operations.
Identifying and Solving Production Bottlenecks
The project began by creating a detailed simulation model of the existing production system. The model incorporated various elements, including:
- Personnel roles and qualification scenarios
- Set-up time optimizations
- Lot-sizing strategies
Key performance metrics—such as inventory levels, work-in-process (WIP), and service level—were tracked and analyzed throughout the simulations.
Validating the Simulation Model
To ensure accuracy and reliability, the simulation outputs were compared against historical performance data from the previous year. The company conducted an in-depth analysis with its partners to validate the model and confirm its applicability to real-world scenarios.
Data-Driven Improvements
Through extensive simulations and analysis, the company discovered several actionable strategies to optimize production, including:
- Night Shift Optimization: Adding a fitter to the night shift improved production flow.
- Set-Up Time Reductions: Minor adjustments to set-up times significantly increased efficiency.
- Lot-Size Adjustments: Reducing lot sizes helped streamline operations.
Tangible Results
By implementing these changes, the automotive supplier achieved impressive results:
- Inventory Reduction: A 10.6% decrease in inventory levels
- Service Level Improvement: An 8% boost in service levels
Why Simulation is Essential for Manufacturing Optimization
This case study underscores the value of simulation in tackling complex manufacturing challenges. By leveraging AnyLogic’s robust modeling capabilities, the company was able to:
- Test multiple scenarios without disrupting ongoing operations
- Identify cost-effective and impactful improvements
- Validate strategies with data-driven insights
Learn More
Explore the innovative work of Klaus Altendorfer, Thomas Felberbauer, Daniel Gruber, and Alexander Hübll to understand why simulation is an indispensable tool for addressing production and workflow challenges in manufacturing.
By integrating advanced simulation techniques, manufacturers can unlock new levels of efficiency, reduce costs, and enhance service levels—all while maintaining seamless production operations.
