Skip to main content
Article thumbnail
Location of Repository

Identifying improvements to the engine assembly line simulation philosophies within Ford Motor Company

By Philip Dewson

Abstract

Ford Motor Company (Ford) utilise unique simulation models to represent the behaviour of their diesel engine assembly lines. The simulation model is a computerised tool used to support modification decisions that affect the assembly processes and productivity of the lines. The stakeholders, who use the simulation outputs, lack complete confidence in them. The doubt appears to stem from a lack of documentation to prove that the model accurately represents the assembly line. This research aims to increase confidence in existing simulation models of the engine assembly lines in Ford. To achieve this, the logic behaviour of the existing Lion Assembly Line (LAL) is analysed. It is found that the LAL can be decomposed into repeatable elements by identifying common attributes and inter-element boundaries. Representational logic diagrams are produced, then verified and validated from the perspectives of key stakeholder functions. The accurate logic diagrams are composed into an Assembly Line Specification (ALS) which is used to identify gaps and correlations between the actual LAL behaviour and the simulated logic. The findings are that the simulation accurately matches reality in the majority of cases. However, there are important differences identified that require consideration during model construction. The research and development completed gave rise to the observation that model confidence could be increased to a greater extent by specifying not only the assembly line, but the whole simulation process. The content and framework identified of such a document allowed the critical analysis of the current simulation strategy within Ford to identify possible improvements to the current philosophies employed. The completion of this research and production of an ALS has increased the confidence held in the simulation model, identified ways to accelerate the modelling process and aid Ford Motor Company to remain a world-class diesel engine manufacture

Publisher: Cranfield University
Year: 2006
OAI identifier: oai:dspace.lib.cranfield.ac.uk:1826/1814
Provided by: Cranfield CERES

Suggested articles

Citations

  1. (1977). A Taxonomy Approach to Simulation Model Documentation, doi
  2. (2004). An Architecture for Web Services Based Interest Management in Real Time Distributed Simulation, doi
  3. (1987). Automatic Model Synthesis: Using Automatic Programming and Expert Systems Techniques Towards Simulation Modeling, doi
  4. (2000). Computer Assistance for Model Definition, doi
  5. (1977). Computer Simulation and Modeling. An introduction, doi
  6. (1983). CVH Engine Assembly Simulation Specification, 1st Edition, Ford Motor Company,
  7. (2002). Documentation of Discrete Event Simulation Models for Manufacturing System Life Cycle Simulation, doi
  8. (2006). Durk-Jouke doi
  9. (2001). Ford's Power Train Operations-Changing the Simulation Environment, doi
  10. (2006). Guide and documentation System to Support Digital Human Modeling Applications, doi
  11. (2005). How to Build Valid and Credible Simulation Models, doi
  12. (2006). Improving the Performance of Engine Assembly Line at Ford, 1st Edition,
  13. (2005). Introduction to Modeling and Simulation, doi
  14. (1991). Linking Simulation Model Specification and Parallel Execution Through UNITY, doi
  15. (2003). NIST XML Simulation Interface Specification at Boeing: A Case Study, doi
  16. (1998). Required Skills of a Simulation Analyst,
  17. (2004). Review of the Government's Manufacturing Strategy, Department of Trade and Industry,
  18. (1998). Simulation applied to final engine drop assembly, doi
  19. (1992). Simulation of Manufacturing Systems, 1st Edition,
  20. (1995). Steps for Proper Simulation Project Management, doi
  21. (1975). Systems Simulation – The Art and Science, doi
  22. (2006). THE SPEECH 'The most important investment we can make will be in the education of our children and young people',
  23. (2006). Torque, Dagenham Engine Plant Quarterly. Summer
  24. (2000). Toward a standard process: the use of UML for designing simulation models, doi
  25. (2003). Towards Composable Simulation: Supporting the Design of Engine Assembly Lines, Foundations for Successful Modeling & Simulation.
  26. (1986). Use of Simulation Gaming to Specify and Validate Simulation Models, doi
  27. (2000). Web-based Modeling and Simulation, doi
  28. (2004). Witness v 2.0 (Manufacturing Performance Version).

To submit an update or takedown request for this paper, please submit an Update/Correction/Removal Request.