Computer modelling of a manufacturing process

DCE is based on the north eastern outskirts of Leicester, is part of the BTR group and manufactures Dust Control Equipment (similar in concept to large vacuum cleaners) for industry. The company employs approx. 500 people at Leicester, having subsidiaries worldwide. The objective of the project, was to construct a component Data Base for the sheet metal work processed by the factory. Leading onto a Computer Simulation Model of the Cut/Punch/Fold operations carried out on this work. The work was to be processed in a "Family" order, similar gauge and shaped work being processed in a set order, to minimise the setting time between jobs. This was achieved, using LOTUS 123 for the Data Base and PCMODEL software by Simcon Ltd. for the computer simulation. With a change in Production Control management came a complete change in Philosophy, towards that of MRP 11. This change was mirrored by the project enabling actual weeks production loadings to be modelled. The comparison of the Family Part Concept/ work processed by gauge(scheduled)/ Kanban processing Iogic/ actual factory production was undertaken. Work processed by gauge was found to be the most effective method of production. When the comparison with the wks) was made; the simulation(2.5 wks) be the most effective method of methodology used by the factory(6 was found to be 59% quicker to completion of a weeks' work. Upon investigation the following points were found to contribute to the discrepancy in times: a lack of rigidity in processing the work, method of employee payment, factory layout, working practice and work station ergonomics.