Company:

Daimler-Chrysler Corporation - Automotive Manufacturer

Objectives:

Created a digital simulation model that was used to assist in production planning. The model was used to determine; Machinery Requirements, Machinery Utilization, Rack Requirements, Rack Storage Space Requirements and Potential Cost and Floor Space Savings.

Results:

An existing manufacturing process was already in place to produce metal stampings. The production requirements were going to increase. The initial project modeled the current machinery running existing part requirements to determine line utilization percentages so a comparison analysis could be run for production increases for model year. Next, the model was used to produce a Rack requirement analysis comparing current plus increased production rates. The model was then used to determine the correct number of Racks and Floor Space requirements necessary to meet production requirements. The model clearly indicated that a proliferation of existing handling racks was not required to satisfy the new production requirements and in fact, an excess number of racks occupying expensive floor space could be recovered at a savings of over $16 million and more than 400,000 square feet.