Investigating rate increase in aerospace factory by simulation of material flow operations

The main challenge aerospace industries are facing in recent times has been triggered by the remarkable increase in commercial aircraft demand. To address this challenge, aircraft manufacturers need to explore ways to increase capacity and workflow through process optimisation and automation. This study focusses on the optimisation of component flow and inventory during the assembly of the A320 Family wings’ at Airbus (Broughton, UK) plant through Discrete Event Simulation (DES). This research measured the likely impact of future changes in the wing assembly process, using simulation by: mapping of component flow from delivery to the point of use, simulation of current logistics scenario (AS-IS), simulation of future logistics scenarios (TO-BE) that include proposed changes for optimising flow and managing capacity surge, and testing and validation of mapping and simulation. The developed DES model demonstrated the impact of changes planned to be implemented by showing a considerable increase in production capacity growth, by achieving a target of 50% increase of aircraft rate/month within one year. It also highlighted the main problems causing blockages and other non-value activities in the process

ANALYSIS OF APPROACHES TO THE MATERIAL FLOW IN THE PRODUCTION PROCESS WITH THE USE OF SIMULATION

Simulation in the production process represents the implementation of processes in real-time and space. Current trends are heading towards the implementation and expansion of various types of automated delivery systems in many industrial enterprises. These efforts are supported by requirements to increase reliability, reduce operating costs and time as well as meet operational schedules. The present article pays attention to the use of simulations, which are supporting tools in ensuring the operation of the production process, focusing on the evaluation and planning of the material flow. The first part of the paper presents a theoretical description of problems in the area of application of simulation tools in the production process with a subsequent focus on material flow analysis. The core of the paper presents a description of the analysis of approaches to material flow assessment, using supportive simulation tools in line with the ideas of business digitization. At the end of the article, the overall evaluation and summary of the issue are described