Use of Simulation and Modelling to Modify a Production System

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This book describes the use of computer simulation applied to the factory environment for an automotive paint shop, in order to analyze proposals for future modification in the factory, to meet a new level of production demand. The painting process occurs in an intermittent production line, with conveying by automatic cranes. The flow shop system consists mainly of blasting, e-coat (electrodeposition) and top-coat (powder) painting operations. The challenge consists of a structured analysis of the production process using scientific methods, in this case computer simulation, and not only the tacit knowledge of the company managers, aiming at speed and a solid foundation for decision-making regarding different market scenarios. The solution was sought considering the knowledge of experts who work in the system, simultaneously with the analysis by production simulation. The research-action methodology was applied as a structure for the computer simulation and modeling. The simulation software used was the Tecnomatix Plant Simulation, from Siemens Company. Considering the results, a reduction of 64% was achieved in the investment required for the proposed capacity increase.