Samples of Past Industrial Projects

The following listed are the projects that are implemented in the field of Production System.
Due to privacy policy, the exact title of the project and the clients are not mentioned. We request your understanding.

Crankshaft Manufacturing(2002 - 2003)
The concept is a new installation for flexible crankshaft manufacturing considering the modern production technology.
The production capacity is estimated to be 400,000 crankshafts per year of variable length. The manufacturing is divided into several cells which are connected to each other by 4 stock segments.  The feature of this simulation study is that it is a highly flexible Simulation model. The customer is able to control a multiple parameters starting from rack feed capacity, speed of rack speed control devices up till the breakdown value of the individual machines.  As a feature, the client is in a position to record the operational sequences of different crank shafts in Excel. Thus to achieve a simulation which was till then not flexible for the customer.

Cam shaft Manufacturing (2002)
The simulation study is provided for 2 stages of developments of a camshaft manufacturing. Due to high demand for flexibility, a temporary buffer is placed between the end of the cam shaft and the loops of the cam shaft. Apart from the function of the plant, the capacity of the temporary buffer and the ultimate waste production disposal were under investigation.
Further investigation the concern on determination of lot sizes for cost reductions are under consideration.

Parameterisation of Bottel Pack Linie – Extension of Study 2000 (2001)
Bottel-Pack Lines 1 und 2 (1999/2000)

PKW-Assembly... (1996)
Simulation study to investigate assembly plant’s new concept for small PKW. As far as possible, the assembling is from the existing module (Cockpit, rear end (Motor, gearbox, exhaust pipe, rear axle), Front (front axle, headlight, bumper). The module assembly took place in the same location of the supplier who merged in Just-in-time concept. The production amounts to approx. 200,000 PKW, the round time is 1,7 min, the turn around time is 8 hours as per the German rule. When assembling there is no discharge possibilities.There are 4 branches of small buffers (approx. 15 mins work content) and they are decoupled from each other. Examined and finished products are arranged in 2 branches and then it is removed in a central remachining field.  The investigation goals were the proof function and the function availability after disturbances, the classification of downtime in the branches after disturbance, Module loss, Operator interference, flaw(the pre-buffer empty) and congestion, determination of the stock in the temporary buffer before the next work place,  die Ermittlung der Durchlaufzeiten und die Ermittlung der erforderlichen Anzahl Werker für den Nacharbeitsbereich.

Final Engine assembly ... (1995 - 1996)
Simulation study for the investigation of an final engine assembly work including the supply of LKW installation (4 lines). Final engine assembly and installation are integrated in a Just-in-time concept. Production amounts to approx. 900 engines for each layer (440 mins). The Motors shall be transported into the assembly of Electrical ly Suspended Conveyors and in the Stock-Shipping divisions with conventional conveyor techniques (Accumulating Conveyor, RFZ, Elevators). The assembly takes place in 3 lines in optimized order (Line allocation of the variants, work contents). The loading takes place on special of transportation deck (without optional access) in installation sequence. Investigation goals were the proof of the function and the function availability with consideration of disturbances, to determine the number of expected „taxi travels“ for the express supply of late engines to the installation, the determination of necessary number of EHB vehicles, die placing and dimensioning of necessary buffers in EHB circulation,  the organization of the remachining range for optimal throughput and the development of tax algorithms for the cycle time regulation of different subranges.

Engine armament including  High time field (1995)
Simulation study for the investigation of a production plant to the engine final assembly including the supply to the installation .The final engine assembly and the installation are integrated in Just-in-time concept.  The input is in time pulse (450 fzg/layer). The engines are developed on Subpaletten, which are promoted when assembling by electric suspended conveyors (EHB) and with the installation on assembly trolleys.
The investigation goals were the proof function and the function availability after  disturbances, the determination of necessary number of EHB vehicles, Placing and dimensioning of necessary buffers in the EHB circulation and the development of a control algorithm for neuralgic points (EHB elevators, delivery of the engines of the EHBs to the assembly trolleys including the cancelling of empty Subpaletten of the assembly trolleys (due to structural reasons, only 2 assembly trolleys and/or 4 EHB lengths) and collection of free EHBs in the special empty buffer.

Basics of computer integrated factory (1991 - 1994)
(Client: Volkswagen AG, Central Training/ advanced training)
Employ Simulators SIMFLEX/2 as a control station of a model factory for the purpose of training to co-workers of VW and to simulate the layout variants in context with the training course. Simulations and Control station software are identical from source code to the executable program (including the run time files). SIMFLEX/2 is for the control station employment and is coupled to standard industry programmable controllers over Ethernet.

Sterilisation Plant (1989)