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Logistic planning: redesing of tugger train concept for assemply hall
Category: Engineering
Process: Production
Introduction
A consistent and innovative material flow concept had to be developed for the internal assembly supply system of a new production hall. This formed part of work to redesign and extend the factory of a German premium segment automotive manufacturer.
The customer chose to work with IndustrieHansa on the basis of its positive experience from previous projects and proven expertise.
Solution: Rather than using forklift trucks, the most common floor conveyor, this project opted for what is known as a tugger train concept for implementing transparent, smooth and pull-controlled processes. This material flow concept is also a crucial step towards improved occupational safety within the material supply system and follows the recent trend towards production with few or no forklifts.
Puncture points
Benefits
Thanks to expert assistance provided by IndustrieHansa, this OEM was able to implement its first ever consistent material flow concept. The concept uses a tugger train and applies to one complete assembly hall. The planning and evaluation work carried out in advance was largely confirmed by an extensive simulation model and the system successfully rolled out on schedule.
back
A consistent and innovative material flow concept had to be developed for the internal assembly supply system of a new production hall. This formed part of work to redesign and extend the factory of a German premium segment automotive manufacturer.
The customer chose to work with IndustrieHansa on the basis of its positive experience from previous projects and proven expertise.
Solution: Rather than using forklift trucks, the most common floor conveyor, this project opted for what is known as a tugger train concept for implementing transparent, smooth and pull-controlled processes. This material flow concept is also a crucial step towards improved occupational safety within the material supply system and follows the recent trend towards production with few or no forklifts.
Puncture points
- Recording of all planning premises for the material flow with regard to
- factory and structure requirements (production model, IT, etc.)
- requirements (hot spots, Sankey diagram)
- material criteria (variety of containers used and compatibility between them, material release orders)
- Evaluation of possible technical concepts (technical tugger train solutions)
- Comparison of alternatives with regard to potential material supply routes (e.g. central vs. local)
- Planning structural requirements (handover points, stations, transport routes, etc.)
- Development and evaluation of the process model (description of process, flow charts)
- Economic evaluation of alternative concepts (business case)
- Simulation-based confirmation of procedural feasibility
- Consistent project management (documentation, implementation plan / road map)
Benefits
Thanks to expert assistance provided by IndustrieHansa, this OEM was able to implement its first ever consistent material flow concept. The concept uses a tugger train and applies to one complete assembly hall. The planning and evaluation work carried out in advance was largely confirmed by an extensive simulation model and the system successfully rolled out on schedule.
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