خلاصه 

Iran Khodro is the largest car manufacturing company in the Middle East & IPCO is its subsidiary company for manufacturing & supplying car engine. Recently has done a lot of effort to optimize energy consumption, decrease environment pollution and use alternative fuel in the world. Thus IPCO started research, design and production natural gas fuel engine instead of petrol one for automobiles in C and D class. Following market research the annual target rate settled 200,000 engines. To design the layout in limited area (3800 m2) & also analyze specification of the production & material handling equipment, considering all of the constraint, resources and facilities, simulation model get developed in Enterprise Dynamics. The length of conveyors, cycle time of equipments, optimized number of required pallets & etc got specified for 2 types of "F" shape & "L" shape of layout. Initial inspection shows that the optimum annual production rate will be 185000 units which is less than target.

اهداف شبیه سازی

The feasibility study of the natural gas production line has been divided into two phases. Although in 1^st phase simulation methodology didn’t get applied to do macro level feasibility study, but in the 2^nd phase, proposed layout has been evaluated by simulation to achieve target production rate.

According to limited area, material handling & machinery constraints initial macro level simulation models get developed & it proved "L" shape layout has better performance than "F" shape type. So L type get accepted as base model for detailed micro design. As the first step, length of conveyors and stations time get determined. Then, we tried find out optimized number of engine pallets, conveyor & crane types & their speeds, bottlenecks, buffers space for raw materials & sub assemblies, to increase the productivity of system & achieve highest production rate using simulation.

After setting initial parameters & required warm up period, sensitivity analyzing based on key variables such as optimized number engine pallet, speed of conveyor has done to guaranty efficiency of the material flow to maximize production rate. All changes were evaluated & tested in enterprise dynamic which leads to reach high performance.

For the next step required logistics system should evaluated to get required production capacity & performance. 

شبیه سازی خط مونتاژ موتور ملی                              

گرم کرردن مدل

Regarding to observation during the 80 hours simulation, this chart illustrated that production rate after 16hours was been stable on 45 per hour therefore we accepted this time as warm up.

تجزیه و تحلیل میزان حساسیت

ü  Change number of pallet

ü  Change speed of conveyor

ü  Change speed of crane

ü  Change station time