Simulation of roll cage manufacture

Industrial Member, Safety Devices Ltd, who manufactures roll bars and cages for the motorsport industry, profited from a computerised factory simulation which brought many benefits at virtually no capital cost, not least by cutting manufacturing lead time in half.

TWI created a computer simulation model of Safety Device's factory and operating practices using an advanved package. Changes to manufacturing procedures were quickly tested using this system, and the effects of lead-time quantified. Recommendations made were to reduce batch size initially to a maximum of five; implement a KANBAN or pull system for production control; and stop rescheduling orders once on the shop floor. This would lead to a manufacturing lead time for a batch of five roll cages of 3- 4 days and for a single cage, less than a day, compared with 2.5 weeks in the old system.

In practice, TWI's use of the simulation package allowed Safety Devices to make cost effective and accurate forecasts of their manufacturing operations. Coupled with the commitment of management and workforce, the following benefits were quickly achieved:

reduced lead times from 2.5 weeks, to 2-4 days - resulting in faster response to customers' orders;
reduced stock levels and lower work in progress - resulting in improved cash flow;
higher output as a result of less confused production scheduling;
fast identification of bottlenecks and high visibility of production problems;
more accurate despatch forecasts;
clearer and more organised working environment.