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Simulation-Based Productivity Diagnosis (Manufacturing Operations Optimization)

Pre-simulating production strategies in a virtual factory built in cyberspace to predict on-site risks and identify improvement points

Solution

Simulation-Based Productivity Diagnosis (Manufacturing Operations Optimization)

Goals

Bridging Physical and Digital — converting Physical to Digital and Digital to Physical, and validating manufacturing site changes in the virtual space.
  • Manual Data
  • Automatic Data
New Factory and Line Construction Plan Review

  • Pre-assess physical and systematic limitations and make adjustments

  • Identify issues in advance and apply improvement measures

Visual and Quantitative Analysis of Existing Manufacturing Site Pain Points

  • Identify problems for each line through existing line simulation

  • Review production volumes and material flow when expanding the factory

Justification of Manufacturing Site Improvement

  • Simulation and reporting based on equipment and process data

  • Enhanced persuasiveness with 3D simulation elements

Procedures and Deliverables

Using virtual models to analyze/evaluate alternatives, derive feasible solutions, and identify maximum/minimum conditions for specific purposes.
가상모델을 활용하여 대안 분석/평가 및 Feasible Solution 도출하고 특정목적의 최대/최소 조건 도출

Application Areas

Process

Workflow Simulation

Material and logistics flow simulation, Line of Balance (LOB) analysis, and shop-floor layout optimization

Value Chain Process Simulation

Modeling of key value chain elements such as suppliers, production, and logistics infrastructure to establish optimal operation plans and derive issue response methods

Optimization

APS/MPS (Production Planning) Simulation

Modeling of dispatching rules for process, equipment, and workpiece selection considering constraints to establish efficient resource allocation and production plans

Real-Time Simulation

Modeling of dynamic target systems with real-time data to derive optimal operating conditions

Advanced
Analytics

Process Parameter Optimization

Considering interactions and dynamic relationships among variables across multiple processes to derive and control optimal process conditions

Expected Benefits

Manufacturing/Logistics Layout Design Optimization

  • Shorten production design time when introducing new lines or equipment Estimate maximum capacity to prevent overinvestment

Manufacturing/Logistics Operation Process Review

  • Identify operational risks, manufacturing losses, and improvement points by applying changes to manufacturing and logistics operations in a virtual environment

Production Management Optimization

  • Establish optimal production plans by considering mass customization order conditions, recipes, and variables

References

Electrical/Electronics Layout Optimization
Objectives

  • Simulation for new line operation and layout optimization

Challenges

  • ACR automated warehouse To-Be modeling

Key Achievements

  • To-be automated warehouse modeling verification and AMR quantity optimization for efficient operation

  • Warehouse layout design verification

Electrical/Electronics Bottleneck Analysis
Objectives

  • Simulation for improving existing line efficiency and identifying issues

Challenges

  • Bottleneck analysis and standard time (ST) verification through As-Is modeling

Key Achievements

  • Justification for APS (Advanced Planning and Scheduling) implementation

  • MES (Manufacturing Execution System) advancement promotion

  • Identification of analysis tasks applicable to other sites

Cable Line Efficiency Enhancement
Objectives

  • Improvement of existing line efficiency through logistics equipment optimization

Challenges

  • Derivation of dispatch rules and optimization strategies for logistics equipment through As-Is modeling

Key Achievements

  • Status analysis and data collection for digital twin project advancement

  • Linkage with infrastructure development and advanced scheduler system integration(SI) projects

Finished Consumer Goods Shipping Operations Optimization
Objectives

  • Simulation of new line operations and layout optimization

Challenges

  • Evaluation of unmanned forklift implementation linked to the finished goods shipping warehouse

Key Achievements

  • Simulation review of operational strategies for stacker cranes and unmanned forklifts

Defense Logistics Resource Optimization
Objectives

  • Simulation of new line operations and layout optimization

Challenges

  • Validation of optimal number of AMRs for material transport between work areas in the new plant

Key Achievements

  • Verification of the To-Be scenario for inter-area logistics transport