Simulation analysis and performance improvement of engine assembly line

Abstract

Simulation is used frequently for performance measurement and improvement. The purpose of this paper is to investigate an existing engine assembly line at Detroit Diesel with a known bottleneck station, and determine the best solution to improve the output of this process and accommodate a future decrease in cycle times. The assembly line uses automated guided vehicles (AGVs) to transport the engines and at this station there is a second path available to add an additional process. A simulation of the existing system is completed, and improvement ideas are simulated and analysed to determine which solution best suits the assembly line’s need for throughput improvement. The study shows significant performance improvement in two automatic system of the valve lash operation. The confidence interval shows lower variability if two-automatic system is used compared to hybrid system. The concern was raised for the manual operation due to ergonomical problems. Flexible simulation shows how to improve the system without disrupting production and operational systems.