3% savings – and confidence the layout will achieve its targets
Using the WITNESS models for the welding and vehicle body production lines, Ford Otosan was able to optimise its design.
Savings came from a range of areas, including
- Previously unidentified bottlenecks that were resolved
- A smart production algorithm to plan the sequencing of vehicle types
- Opportunities to achieve robot and operator efficiencies
- Cycle times that were out of sync with forecasts and could be improved
- Preventative measures to mitigate the effects of breakdown
Particularly useful was the ability to understand production capacity 12+ months after opening the factory, so Ford Otosan could analyse performance over the long-term in a risk-free way – and adapt its planning and operational approach accordingly.
“Simulations are now indispensable for building high-efficiency lines at the design stage. Our high-tech production lines, where we will produce electric vehicles, will have simulations that are used not only during the design phase, but also after mass production starts. These simulations will turn into a decision support system by processing real-time production data. We are proud of commissioning a digital twin project for the first time at Ford Otosan,” said Omer Faruk Senocak, Data Analytics and Simulation Engineer at Ford Otosan.
Based on the success of this project, Ford Otosan and CodeArt are now using WITNESS to build predictive digital twins of the paint shop and assembly lines, ultimately providing an integrated simulation model of all manufacturing processes for the electric transit factory. This will enable simulation to be a cornerstone of Ford Otosan’s ongoing operational planning, helping them leverage data and Internet of Things investments in line with their digitalisation strategy.
“With the help of WITNESS simulation modelling, it is a great advantage to verify the feasibility of new production facility projects and to see opportunities before investment realisation. We are also taking the most important step towards digital twinning with WITNESS,” said M. Nejat Tanca, New Technologies and Smart Factories Leader at Ford Otosan.