Vehicle Assembly – Floor Pan Build System

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Mechanic engineer holding a digital tablet with engineering research software application on the screen, aerodynamic test of parameters data in the wind tunnel of an eco-friendly car body

PROJECT

Floor Pan Build System

CUSTOMER

General Motors Corporation

Objectives

  1. Analyze the system and identify potential bottlenecks.
  2. Evaluate the systems’ throughput at 100% capacity, with allowances for probable unscheduled downtime.
  3. Evaluate “what-if” scenarios to improve system performance to a gross of 115 JPH.

Description

Floor Pan Build System consisting of material handling and shuttle robots, welding robots, operators, turntable stations, and part sub-assemblies.

General Methodology

A baseline simulation model was developed reflecting the current operating conditions of the Floor Pan Build System. An analysis verified that the system’s operationallogic and cycle times could support the measured gross rate, taking into consideration process interaction, but without the effects of downtime. A net rate analysis was performed employing downtime data derived from actual observations. The data was analyzed, filtered and incorporated into the model when evaluating the impact of downtime on the system. Experimentation with respect to cycle time reductions was performed with the objective of achieving a target gross throughput of 115 JPH

“Bottom Line” Results

BASE MODEL:

Gross Throughput –> 99.6 JPH
Net Throughput –> 85.0 JPH

AFTER CYCLE TIME CHANGES:

Gross Throughput –> 114.6 JPH
Net Throughput –> 97.5 JPH

Recommendations on ways to reduce cycle times in “arious al8Bs went offered, and included in the final report. For example, regstrling shuttle robots 10 and 19, the suggestion was made to eliminate the shuttle robots’ staging movements, thus eliminating redundant parts handling and reducing cycle times.

Material Handling Systems – Preform AGV Delivery System

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Automated Guided Vehicles

PROJECT

PreformAGV Delivery System

CUSTOMER

Western Container Corporation/Coca Cola

Objectives

  1. Evaluate and test the AGV systems’ throughput capability under anticipated operating conditions.
  2. Verify that eight AGVs will maintain throughput demands.
  3. Compare the effects of one, two or three home stations (AGV park empty waiting for next pick-up task).

Description

Automated Guided Vehicle (AGV) pick-up from 12 additional preform machines and delivery to automated bin unload station.

“Bottom Line” Results

AGY system can service 24 preform machines without ever impacting preform machine throughput (blocked by full containers).

One home station (empty AGY parking) provides the greatest flexibility and quickest response time to waiting machines.

System would meet production requirements with as little as five AGYs, indicating excess system capacity.

Material Handling – Large Package Sorting System

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Package sorting system

PROJECT

Large Package Sorting System

CUSTOMER

United States Postal Service

Like all USPS processing plants, a Bulk Mail Center (BMC) must use its resources wisely to meet the challenges of a changing mail processing environment.

Presently, package piece count is increasing 20 to 70% annually, prompting the BMCs to request installation of a Large Package Sorting System (LPSS). Without these systems, package volume will overwhelm BMCs in the near future, causing a degradation in service and higher costs due to an increase in manual processing.

The LPSS operates within BMCs and other USPS mail processing facilities to sort large parcels. Systems include a sorter and equipment to deliver and take away product from the sorter. The configuration of the system is site-specific depending on the space availability, package count, and number of distributions required.

These are the important points relative to the LPSS project.

Flexible Model for Evaluating LPSS Systems

The simulation was constructed with distinct modules, such
as singulator, scanner, etc., so that different configurations
could be easily modeled.

If different configurations are modeled, floor space requirements may be more accurately quantified after determining the effectiveness of the new system.

Package Sort Plans

The simulation model was tested using one sort plan. To optimize the number of runouts, changes must be made to the sort plan and the staffing of the runouts. Alternatives include:

  • Combining low volume runouts and having multiple pallets at one runout.
  • Splitting up high volume runouts to ease workload and minimize “full” conditions.
  • Using multiple operators at single high volume runouts.

Overall

The highest impacting deficiency in the LPSS system today is the sweep operation at the end of the runouts.

The uneven distribution of packages to these runouts decreases sweeper utilization and increases packages sent to the mis-sent runout, which is less efficient than the regular runouts. Optimizing the sort scheme will correct a large part of this problem.

Material Handling – Finished Paper Roll Handling System

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Paper Roll Handling System

PROJECT

Finished Paper Roll Handling System

CUSTOMER

Appleton Papers, Inc.

Objectives

  • Evaluate and prove the AEM system’s ability to meet the design throughput requirement of 5100 rolls per day.
  • Identify any deficiencies (bottlenecks) in the system flow and determine potential design improvements.
  • Assist with controls development, including flow logic and AEM path zoning to insure design throughput objective is reached.
  • Evaluate each order sortation area’s ability to meet the design throughput requirement.

Description

System 1: Automated Electrified Monorail (AEM) delivery of cut paper rolls from nine rewinders to seven wrapping machines.

System 2: AEM delivery of wrapped paper rolls from seven wrapping machines to four order sortation areas.

System 3: Palletized order sortation using semiautomated bridge cranes.

“Bottom Line” Results

System can achieve 5100 rolls per day requirement Detennined optimum dispatch locations for empty AEM vehicles. Developed dispatch algorithm for empty vehicle selection of rewinder pick-up location. Developed AEM path flow logic to minimize vehicle flow restrictions through the following methods:

  • AEM track zoning
  • Vehicle priorities
  • Pick-up/Drop-off decision logic

Determined minimum vehicle requirements of 12 for system ‘1 and 15 for system 12. Vehicle costs were $80,000 and $30,000 for systems ‘1 and 12, respectively.

Simulation Engineering

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Simulation Engineering

Do It Right The First Time

Design Systems, Inc.’s simulation engineering experience spans more than 20 years and cumulative staff experience more than 100 years. The process involvement over these years has been in a multitude of industries.

The most critical component of simulation engineering analysis is the ability to understand the dynamics of a system and then translate that understanding into a simulation model that will accurately reflect the system(s) and its dynamic interactions. This analysis allows your project goals to be quickly and accurately validated.

Strain Gauge Link

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Strain Gauge Link

Design Systems, Inc. proudly introduces an additional offering to its growing list of Conveyor Health Assessment services. The tension of the chain can be measured through the length of the conveyor with a Strain Gauge Link.

Strain Gauge Link Benefits:

  • Maximum tension in chain and location of the tension
  • Compare real tension data to theoretical Chain Pull results to avoid adding unnecessary drives
  • Chain Pull at each drive for the current load condition
  • Rolling friction of chain to verify lubrication effectiveness
  • Air pressure needed at take-up to give minimum system tension
  • Pulsing of chain tension from engagement with the drive’s cat chain
  • Link can be shipped, installed and removed by plant personnel, then returned for data processing, to limit engineering time in the field
  • Results presented on a graph of tension vs length of conveyor

Temperature limit is 170°F due to battery limitations. Higher temperature applications are possible with the data logger in an insulated enclosure attached to the chain.

Other Possible Configurations:

Drive Monitor

A Strain Gauge Link will show the difference in tension before and after it passes a drive. A drive monitor sensor will show the Chain Pull at the drive for varying load conditions that occur during the day. Results are presented on a graph of Chain Pull vs. time to determine maximum pull of the drive.

Carrier Rolling Friction

A tension sensor can be used to measure individual carrier pull by temporarily attaching to the preceding carrier. This will give actual rolling friction for the carrier wheels to use in Chain Pull analysis, instead of a theoretical value.

Custom Installations

Strain Gauges can also be added to the framework of a conveyor turn that is at the lowest tension in the system. When the loads vary, the take-up air pressure can be adjusted with feedback from the gauges to keep chain at the lowest tension which reduces wear.

“BOTTOM-LINE” RESULTS:

  • Tension Monitoring
  • Performance Visualization
  • Minimized Downtime
  • Cost Saving Opportunities

Conveyor Training

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classroom training

Have a conveyor system but not sure you are fully utilizing its functionality? Maintenance issues causing unexpected costs, personnel time and downtime? Design Systems, Inc. has been providing Conveyor Engineering Services for our customer’s material handling needs since 1983. As an engineering service provider and not an equipment supplier, we are a completely unbiased engineering resource whose only goal is to design the best possible solution for our client’s unique circumstances.

Let us help you get the most out of your conveyor systems; understand its capabilities, maintenance requirements and design parameters. Classes offered by Design Systems experienced team of engineers can be tailored to your specific conveyor systems and will typically run from a 1-day overview session to a more in-depth week long class.

Save Maintenance Costs – Do it yourself

Conveyor EngineeringThese training classes are designed to teach facility personnel the fundamentals of Conveyor Systems Engineering so they will have an understanding of each system’s overall functions and capabilities.

This systems-oriented course is ideal for cross-training plant personnel. People who will benefit from attending this course include:

  • Plant and Facility Engineers
  • Supervisors
  • Building Engineers
  • Safety Directors
  • Environmental Health and Safety Personnel

Conveyor Systems Included in the Course Overview

  • Overhead Power and Free
  • Inverted Power and Free
  • Skillet System
  • Chain-On-Edge System
  • Skid System
  • Flattop System
  • Power Roll and Belt Systems
  • Basic Transfer Methods

Topics Covered for Each System

  • Chain Pull Calculations
  • Throughput Analysis
  • Horsepower and Drive calculations
  • Take-up Calculations
  • Clearance Studies (Horizontal and Vertical)
  • Min / Max / Float Calculations
  • Zone Counts
  • Strip Out Bank Calculations
  • JPH Calculations
  • Basic Carrier Designs and Carrier Quantity Analysis
  • Basic Transfer Designs
  • Horizontal Turn Studies and Rules
  • Vertical Curve Studies and Rules
  • Accumulation Studies
  • Trolley Load Studies
  • Load Bar / Tow Bar Studies and Rules
  • Basic Carrier Troubleshooting

3D Facility Layout Development

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3d rendering manufacturing

3D Design is reality in Design Systems, Inc.

Design Systems, Inc. uses a broad suite of 3-D design software, including, to name a few, CATIA, Unigraphics, Solid Edge, AutoCAD, FactoryCad. Visualization and animation software include: UGS Teamcenter Visualization Quality and 3-D Studio Max.

Facility Layout Development

Design Systems, Inc. applies its 25 years of experience with facility and material handling engineering to the development of comprehensive 3-D plant layouts.

  • Native 3-D drawings conversions
  • 2-D to 3-D drawings
  • Field check to 3-D drawings
  • Laser Scanning to 3-D drawings
  • 3-D to AVI “Fly throughs” Development of 3-D concept and Bid Package level layouts for facilities and conveyor systems.
  • Development of material handling and material display layouts.
  • Layout support using “Smart Object”

Work Cells/ Workstations

From the 3-D layout model, any workstation or cell can be isolated allowing:

  • Identification and study of the workstation and it’s environment, including carriers, racks, tools, rails, etc.
  • Analysis of operator workflow and packaged materials within the work cell.
  • Confirmation of work elements required within the workstation.
  • Review and analysis of ergonomic issues.

Uses of 3-D Layout Design

    • Exceptional presentation tool
    • Interference Detection
    • Coordination, and validation of tooling design / location
    • Quick development of cross-sections
    • Validation of service accessibility
    • Operator training
    • Visual management

“BOTTOM-LINE” RESULTS:

  • Error Reduction
  • Interference Resolution
  • Clarity Through Visualization
  • Cost Reduction By:
    • Design Optimization
    • Ease of Change Management
    • Team Integration and Coordination
    • Decision tool for Management

3D Carrier Design

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s a core competency, Design Systems, Inc.has extensive “hands-on” experience with 3-D carrier design and virtual modeling.

CATIA V4 & V5 and Unigraphics software are used for the design of carriers and fork transfers. These design tools provide customers with better and more accurate detail design, thus reducing the number of prototype carriers required for testing and design proofs.

Using Finite Element Analysis (FEA) software with the 3-D models, Design Systems can “Right Size :” the structural elements of the carriers for both static and dynamic loading. This eliminates “Over Sizing” of carrier members which reduces cost in carrier fabrication, conveyor drive HP requirements and conveyor system wear.

Our expertise with 3-D software and “big screen” conferencing facilitates highly effective coordination with the client and suppliers. It also reduces carrier design time allowing best possible communications regarding design intent and decision -making.

Design Systems has the ability to connect with our customers via:

  • T1 Lines
  • Virtual Product Manager (VPM)
  • AutoWeb CCX-I Mailbox
  • AutoWeb GCX-I Mailbox

“BOTTOM-LINE” RESULTS:

COST SAVINGS:

  • “Right Sizing” carrier structures.
  • Design carriers accurately the first time.
  • Multiple product capability using product math data.
  • Early design to allow coordination with suppliers.
  • Early design allows prototype build at customer facility.

TIMING

  • Minimize prototype development.
  • Minimize launch issues.
  • Minimize vendor coordination errors.

Schedule Management

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industrial engineering consulting

The adage, “If you fail to plan, you plan to fail”, has proven itself all too well repeatedly, in the implementation of manufacturing capital projects. All projects require planning, whether they are small weekend change over projects or large multi-million dollar new plant construction projects. DSI’s scheduling team, led by a Project Management Professional, can provide you the tools and services to successfully manage your next project.

Program Scheduling

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Project Management

PROJECT

New Assembly Plant Paint Shop Construction and Installation

CUSTOMER

Chrysler Corporation

Objectives

    • Develop a condensed, reliable, executable and controllable installation plan
    • Establish advanced project summary and risk reports
    • Control costs in a centralized system
    • Provide for change control
    • Provide for a clear understanding of expectations for all team members
    • Provide for forecasting capability

Description

Customer wanted to improve the current system of program management by obtaining better control of the project plan, execution, change control and invoice validation, while maintaining a clear understanding of all team members’ expectations. Design Systems provided the Program Management manpower and systems to achieve the customer’s goals.

“Bottom Line” Results

  • Detailed work plan in place four months before installation allowed contractors and partners to schedule shop fabrication, field crews and materials.
  • Schedule development used a process that required the installation strategy and plan to be thought out in detail.
  • Forecasts, invoices, progress reports, and summaries were available automatically on a regular basis.
  • Exception, deviation and change control mechanisms provided complete communications and risk lists for special consideration.
  • Project launched on-time and within budget with good results.

Product and Process Integration

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Product Process Integration

PROJECT

Integrate New Product Process into Existing Plant

CUSTOMER

Blue Diamond Corporation

Objectives

    • Integrate new product into existing plant with existing product, with minimum impact to existing operations.
    • Establish facility impact to line with detailed cost and timing.
    • Determine labor impact for new volumes and new product with existing product.
    • Establish throughput analysis on critical path operations.
    • Recommend improvements to achieve new plant goals.

Description

Introduce new Joint Venture product into an existing truck plant in Mexico without disruption to existing operations, while increasing plant capacity for new requirements.

“Bottom Line” Results

  • Introduced new model at new volumes as planned.
  • New Product Introduction with minimal scheduled downtime.
  • Quality indicators higher than similar product produced at other facility.

DSI was later awarded project to pre-plan next product to be introduced into plant.

Process Improvement

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Process Improvement

PROJECT

Stamping Plant Material Handling for Overseas Part Shipment

CUSTOMER

Chrysler Corporation

Objectives

    • Develop methods to allow direct shipment of stamped parts to an overseas plant
    • Develop layout changes needed for implementation
    • Determine production and material handling labor requirements
    • Develop implementation approach and schedule
    • Simulate material handling operations to verify recommended methods and layout changes

Description

Current operations required a U.S. stamping plant to send all parts for overseas shipment to a third party to “repack” parts for shipment. The project studied current operations, identified packaging, method and operational improvements to allow direct overseas shipment of required parts.

“Bottom Line” Results

  • Created a detailed plant layout with optimized material flows.
  • Verified recommendations with material handling simulation.
  • Eliminated “repack” operations saving $1 million per year.
  • Developed detailed implementation plan and schedule.

Process & Facility Launch Readiness

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Distribution warehouse

PROJECT

Plan, prepare and execute a successful new product launch.

CUSTOMER

DaimlerChrysler

Description

Introduce new product into an existing truck plant in USA. Incorporate new process, equipment and layout requirements according to schedule. Launch new product from start of Prototyping through Volume Build.

Objective

  • Facilitate process requirements development.
  • Identify all key product launch personnel.
  • Establish readiness criteria.
  • Establish a check and balance mechanism to track and report progress and issues resolution.
  • Facilitate issues ownership and countermeasure development.
  • Validate launch readiness.
  • Facilitate continuous process improvement throughout the planning and execution process.

“BOTTOM-LINE” RESULTS:

  • Involves all key players early in the planning stages.
  • Successful new product launch on schedule.
  • Production Acceleration objectives met.
  • All cost objectives met.
  • Manpower efficiency objectives met.

Quality System Upgrade

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Optimized work station

PROJECT

Pentium-Based Architecture Development

CUSTOMER

Chrysler Corp.

Objectives

  • Identify and evaluate alternatives for implementing a PentiurnlNT-based system for Chrysler Information Systems.
  • On an operational level, develop a method of containing problems wIThin the workstation where a defect occurs, or inside a group of workstations within the assembly. Ensure that defects are attributed to the proper vehicle through a tracking image that is integral to the vehicle 10.
  • Develop and implement a ‘next-generation’ ALS (Automatic Une Stop) system that is PentiurnlNT-based and user-friendly, and that offers effective and efficient operator communications. Provide appropriate hardware and software to interface ALS WITh the quality system.
  • Using Belvedere as the beta SITe, complete the transition from the existing PLC-based Quality Alert System (QAS) to the new PentiurnlNT-based system. Integrate the new archITecture WITh related plant systems.
  • Concurrently, engineer and implement an automatic vehicle identification system (AVI), and new plant communications protocols.

Description

QAS encompasses the floor and middleware layers of Chrysler’s quality system, linking operator actions, tool faults, and other events with supervisor actions, upper-level controls, and plant communications. Its apex is the corporation’s Performance Feedback System, a mainframe application that maintains quality documentation for assembly operations.

Design Systems identified practical alternatives and evaluated
with the customer, the best design concepts. The advanced
PC-based QAS architecture uses Allen-Bradley’s SoftLogix 5

“Bottom Line” Results

  • Successful installation at Belvedere in 1998 paved the way for corporate-wide implementation.
  • Among the most direct benefits is the ability to reconfigure the QAS system remotely from most anywhere on the globe.

Material Handling

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Conveyor Belt Transporting an Engine

PROJECT

Engine Delivery System Upgrade

CUSTOMER

GM Lansing Delta Engine Plant

Objectives

  • Determine the root causes of conveyor downtime and malfunctions, particularly with problems related to misreads of barcodes and miscounts.
  • Reduce the required maintenance on the system.
  • Improve the maintainability of the system .

Description

Engines exit the final assembly line and are transferred to a power and free delivery conveyor. The engines are hung from the power and free carriers using chains. The existing optical barcode reader had difficulty reading the engine barcodes due to differences in product size and the swaying motion of the engines. As a result, engines were often routed improperly.

Design Systems, Inc. identified the problems and developed concept solutions and budget estimates for client review. GM was impressed with the concepts and approved the program. Design Systems worked with the plant to implement the new concepts as follows:

Replace the optical barcode reader system with a Radio Frequency-based system. RF tags were mounted to the stable carrier, rather than the swaying engines.

Remove all of the tracking software from the Modicon processor. This dramatically reduced the size of the PLC program, and made it easier to understand and maintain.

Improve the existing Modicon PLC Logic to enhance reliability.
Develop a “User-Friendly” operator graphics interface to improve maintainability and system visibility.
Combine the functions of the operator graphics interface and the RF tracking system into a single computer.

“Bottom Line” Results

  • The project was completed on time, and on budget.
  • I The power and free conveyor performs very well with a dramatic reduction In falkns.
  • I The system Is more user-friendly and maintainable.

Electrical and Controls Engineering

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Programmable Logic Controller

Design Systems, Inc. provides customers with the unique ability to emulate and verify their controls logic for new or modified systems

Capital Investment Savings by Improving Project Start-Ups

Emulation uses a Programmable Logic Controller (PLC) connected to the graphical features of a detailed simulation model, replicating the production environment. The PLC, responds to inputs received from the model just as it would on the production floor. Reciprocally, the model responds to the PLC outputs, as would the actual control devices present in the factory. All inputs and outputs of the system are validated using emulation, including manual operator stations and hardware interlocks.

The Design Systems, Inc. emulation process establishes a virtual environment for a material handling system with full functionality, feedback, and a 3D graphical view of the complete system. It also creates representations of control panels and allows the common field faults to be applied to the PLC logic. This environment allows an entire material handling system to be analyzed in an office setting without impacting production. We also have the ability to easily stage test scenarios and run the system at full volume to verify capabilities.

Emulation provides a variety of checking mechanisms to allow the customer and the project partners to verify that the deliverables are in compliance with the scope of work, proper standards, and control methods. It also affords the ability to interconnect and effectively test associated control and diagnostic hardware prior to plant installation, further reducing start-up time and providing additional cost savings.

Design Team Integration

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Process Development

PROJECT

Tray Management

CUSTOMER

Siemens
Electrocom L.P

Objectives

  1. Partner with Siemens Electrocom L.P in the development of an integrated design approach to tray management (TMS) that could be implemented in facilities nationwide.
  2. Bring together talent from diverse disciplines to most effectively address the many issues regarding mechanical systems, controls, ergonomics, material flow and facility compatibility.
  3. Evolve detailed simulation strategies that would allow viable alternative ideas to be understood and evaluated by the customer, quickly and thoroughly.

Description

A Design Team that included representatives from Siemens Electrocom L.P. and Design Systems’ Mechanical, Manufacturing, Controls and Simulation Groups combined their resources in this landmark project.

Optimization layouts created by engineers on the team demonstrated the potential and nature of product flow throughout individual facilities.

DSI engineers provided detailed construction plans and other vital support documents.

“Bottom Line” Results

  • The Integrated Design Team Approached has provided a very effective strategy for engineering these postal systems.
  • Design Systems, Inc. takes great pride in teaming with clients. We have been an effective engineering partner for Siemens since 1996.