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CASE STUDY AUTOMOTIVE
SIMOGGA™ THE FACTORY DESIGN TOOL
Consultancy Support on a change management project with the objective to improve the productivity of its automotive customer
TECHNICAL DATA
Customer location Flemish Region, Belgium
Business challenges Improvement of the factory’s efficiency by reorganizing the location of machines and storage areas
Keys to success • Easy to use • Accelerates the change process • 2D factory layouts everyone can
understand • Immediate assessment of KPIs • Need few amounts of data to
perform the analysis • Automatic identification of product
families • Identification of machines that are
under or over-capacitated
Results • ±11 % decrease of flows within
the production unit • 700 hours gained annually
changing 3 storage locations • Moved from a “Stock where we
can” situation to a “Define best Optimal storage location for each spare part or raw material”
• New layout plan with incremental modification and a cost/benefit analysis for each step
The customer The final customer is specialized in the building and assembly of trucks in Europe. Our direct customer is a firm specialized in change management.
The project Our partner, the change management project leader, asked AMIA Systems for help in achieving the goals fixed by their customer. Our partner could fulfill half of the goal with their usual Lean tools and through the use of SIMOGGA they have managed to achieve the project requirements 100%. Before working on the complete hall (5000 m2), SIMOGGA was used on a small assembly line to define the optimal location of a new machine for a new production line compliant with legislation Euro6.
The solution The new layouts have been formed with SIMOGGA, a graphical material’ handling system enabling engineers to optimize factory layouts based on a global material flow analysis using small amounts of data. SIMOGGA optimized the functional layouts by converting them into working cells or departments. The easy to use interactivity of SIMOGGA allows a collaborative approach with all actors implied in the change process.
The results AMIA Systems revised the structure of the different assembly lines. Using our expertise in combination with the customer’s input and the criteria they defined, several scenarios have been proposed by AMIA Systems. SIMOGGA allowed us to visualize and quantify these scenarios as well as to finalize some discussions with the plant manager and the unions. The chosen scenario highlighted some quick wins (700 hours/year) without additional cost. New layout proposal with incremental modification have been presented with a cost/benefit analysis for each step (kilometers, hours and euros). By decreasing the amount of kilometers, the benefits was about 2 men-year for the transportation. These operators could be dedicated to other activities and increase the productivity of the company.
AMIA Systems AMIA Systems develops visual, simple and interactive solutions to facilitate the organisational improvements of production/maintenance sites and warehouses. Human oriented, our softwares allow to create together the solutions for tomorrow.
Contact Emmanuelle Vin M : +32 479 727 905 @ : [email protected]
AMIA Systems S.A. Drootbeekstraat 13 1020 Brussels, Belgium www.amia-systems.com
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