In this case study, we'll show you how MIDEA, the world's largest producer of major appliances, used Visual Components to improve the capacity and flexibility of a high-end washing machine assembly line while reducing costs of 15%.
The World's Largest Producer of Major Household Appliances
Founded in 1968 and based in southern China, Midea Group is the world's largest producer of large household appliances and number 1 in air treatment products, air coolers, kettles and rice cookers. The laundry appliances division includes a Digital Center, which is made up of a team of simulation engineers who are responsible for verifying product design, molds and equipment, as well as robotics, logistics and implementations of factories.
A Unique Project With Complex Requests
In 2018, Midea Group initiated a project to launch a flexible assembly line producing high-end washing machines. This new assembly line was to be built at the Wuxi site of Midea's laundry appliance division in Wuxi, China. In addition to producing high-end, high-quality washing machines, Midea wanted the line to be scalable to accommodate orders for custom, bespoke washing machines.
The simulation team was responsible for verifying the designs and layout of the assembly line and reporting on how it could be optimized.
While the margin on these high-end washing machines was higher compared to the washing machines Midea was already producing, the production requirements were becoming tougher. There were higher technical control requirements in terms of materials, processes and finished products. Due to complex production and planning requirements, the assembly line needed to make greater use of intelligent manufacturing capabilities and provide flexible production capacity.
A specific aspect of this project is the fact that this assembly line needed to produce over 10 different product platforms as well as over 100 SKUs at the same time. All this in a random manner, with each product having its own cycle times, material requirements and quality control procedures. This involved the rearrangement of over 100 processes, which were completely different from the mass production models previously used.
Taking the Step With Visual Components
“As a comprehensive and professional simulation tool, Visual Components played a very important role in this project,” said Kong Fanshi, Ph.D, a simulation engineer on the Digital Center team. “Previously, we used 3 different software programs to create 3D layouts and check equipment, logistics and production capacity. »
The software Kong and his team used to create CAD models and 3D plans was cumbersome, especially when modeling complex machinery and equipment. The extensive library of parametric and reusable models included in the Visual Components e-catalog made model creation simple for Kong and his team.
Another challenge they faced was the lack of compatibility between their CAD software and their equipment simulation software; importing models was not easy. Once they were able to import the geometry, modeling the models' movements and behavior was complex. They experienced similar challenges with their logistics simulation tool; complex programming and long work. They found that modeling components and creating processes with Visual Components was much faster and easier. They also liked the high-quality graphics and video rendering.
After a brief trial period, Kong's team was using Visual Components as their primary simulation tool.
“As the additional advantages offered by Visual Components compared to other software were obvious, we gradually turned to the software to simulate most cases of our projects,” explains Kong.
Kong and his team use Visual Components to design, optimize, and verify the processes and production feasibility of the layout for the washing machine project, as well as to dynamically present the assembly line layout and logistics flows to Midea managers and project stakeholders.
“As a comprehensive and professional simulation tool, Visual Components played a very important role in this project,”
Kong Fanshi, Ph.D, a simulation engineer of the Digital Center team, Midea Group
Verification of the Design and Implementation of the Assembly Line
More than 100 components must be assembled to produce a high-end washing machine. The entire assembly line project included 3 main assembly lines.
1. The tank
The tub assembly is formed by placing an inner tub into a rear tub and then sealing it with a front tub
2. Box assembly
A steel plate is made into a steel box using a horizontal punching machine. Accessories such as flexible pipes and wires are installed on the box, forming the box assembly.
3. Assembling washing machines
The tank and box assemblies, together with the balance block, control panel, door and top plate are assembled to form the finished product.
Kong and his team faced two major issues with this project. The first was how to detect problems during the design phase and avoid running into problems during construction and implementation, when it would cost much more to fix them. Simulation was essential to overcome this problem. “We used simulation to verify our design,” says Kong. “We actively looked for risks in the design and used simulation to minimize or eliminate their effects. »
The second problem was to find the best solution to meet the requirements and aggressive objectives of the project. Kong's team used simulation to optimize their design. As an example, they ran over 100 simulation cases to find the best assignment for operators.
“The methods we used to overcome these challenges were previously unimaginable,” says Kong. “You couldn't easily find the solutions without actually building and testing the line. »
“With Visual Components, we can easily design, simulate and verify all kinds of solutions in a virtual environment. »
Kong Fanshi, Ph.D, a simulation engineer of the Digital Center team, Midea Group
Beyond the Project Objectives
With a relentless focus on optimization and improvement, Kong's team was able to achieve significant improvements and savings over their original design, starting with more efficient use of floor space.
“We reduced the assembly line floor space by 10%, while increasing production capacity by 10%,” says Kong. “The line had sufficient capacity to produce 500,000 units per year. »
The line was able to accommodate mixed flow production of over 100 SKUs, compared to the normal 5-10 SKUs. Despite the more complex production process, the line was also more balanced. “The balance of the line has been improved by 20%, reaching over 90%,” says Kong.
Kong and his team were also able to achieve significant savings through more efficient management and utilization of personnel, such as operators, logisticians and quality technicians.
“We were able to improve product quality, reducing the rejection rate by 1,200 defects per million at 120 dpm,” says Kong.
Finally, Kong and his team were able to accelerate the construction and installation of the complete assembly line.
“We reduced the construction period from 15 to 12 weeks, achieving a 20% savings on the schedule,” says Kong. Total savings for the project were approximately $879,000.
“Using Visual Components, we were able to reduce capital costs, as well as find significant efficiency improvements,” says Kong. “As a result, the total project costs were reduced by approximately 15%. »
After the line was built, the project manager set up a large television near the assembly line to show how Visual Components impacted the project. It continuously plays a loop of 3D layouts and simulation recordings that Kong's team created for the project.
Futuristic Look With Visual Components
Following the success of this project, Midea plans to explore how they can continue to use Visual Components in the design and commissioning of their production systems.
Kong and his team want to further customize the software for their applications and develop their own plug-ins and add-ons. “Visual Components' open platform and interfaces give us the freedom to expand the applied range of simulation tools,” says Kong.
Industry 4.0 is another priority for the Kong and Midea team. They are looking to digitize their production and make their factories more connected.
“We want to build a digital twin of our production,” says Kong.
“We plan to collect data on the factory's machines, logistics and production and visualize it in Visual Components. »
“We also want to explore how we can use Visual Components PLC interfaces to provide controls to our production assets. »
About Midea
Founded in 1968, Midea is the world's largest producer of major household appliances and number 1 in air treatment products, air coolers, kettles and rice cookers. The company specializes in air handling, refrigeration, laundry, large cooking appliances, large and small kitchen appliances, water appliances, floor care and lighting.
Midea, headquartered in southern China, is a truly global company with more than 100,000 employees and operations in more than 200 countries. The company has 21 production sites and 260 logistics centers around the world.
