Many companies test their factory expansion plans through simulation before final investment. Process modeling software allows you to discover problems and find solutions in time.
This article is an adaptation of an original article by Visa Noronen published in the Automation special edition of Helsingin Sanomat (in Finnish). Read the original article – Image: Eino Ansio
The challenge: process modeling for the expansion of a factory
AGCO needed to expand its diesel engine plant in Nokia . The Linnavuori plant manufactures around 30,000 diesel engines per year, mainly for agricultural machinery.
The investment would be significant, so it had to be managed carefully. Before ordering new equipment, AGCO decided to run a simulation of its planned component machining system.
For the company, simulation meant a realistic virtual imitation of its expansion plan.
Using process modeling software
“ AGCO Power told us about the plans for the different stages of production. After that, we entered the scenarios and ideas into the simulation software, taking into account products, machines and stock . Based on this data, we were able to create a three-dimensional computer simulation of planned operations . AGCO Power was able to try to operate the factory on screen as if playing a video game ,” says senior consultant Jouni Eronen of Jetecon.
Game-style simulation is used to test whether everything in the plan is working as expected and what details need to be changed.
By using process modeling software , you can test to see if robots and objects move smoothly .
Testing also reveals any bottlenecks that could slow down the process. At the same time, the simulation gives the factory designers ideas on how the layouts could be further improved.
Using simulation, AGCO Power was able to improve its plans . For example, where bottlenecks caused by insufficient equipment have been detected, they could be resolved by adding more equipment. Conversely, some equipment could be removed from the plans if the simulation suggested that a smaller number was sufficient.
“ Simulation is becoming increasingly important as the variety of products increases and their life cycle shortens ,” adds Yli-Jama.
AGCO Power also used simulation to compare the suitability of solutions from different equipment suppliers to its production .
The growing popularity of simulation
Process modeling software proven to be adequate improves the competitiveness of the company and ultimately pays off financially.
“ More and more companies are running simulations of their plans before making final investment decisions ,” says Mikko Salminen, sales director at Visual Components.
Companies are running simulations more often because it also speeds up the planning process . The same simulation tools can be used for different aspects of production, from manufacturing and packaging lines to robotics.
“Our tools are increasingly used to test entire processes. The simulation goes through all material flows and the use of robotics is integrated as part of the whole »
Visualizations are also becoming more and more realistic. Computers are becoming more advanced, allowing for fine detail and more engaging virtual reality.
Simulation software can also be directly connected to management systems and machines that will be used in the future . This gives an increasingly detailed picture of what happens if the plans are implemented. This has significant benefits, especially as systems become more and more complex.
“ This need arises during the planning stages of investments and changes, especially if the site in question is complicated, has parts that are difficult to define or the risks associated with implementation need to be minimized,” explains Eronen .
AGCO Power used factory simulation when expanding its diesel engine manufacturing line . This paid off as the simulation eliminated bottlenecks in the initial plans.
Factory simulation is like a game that shows how the line works.
Benefit from the benefits of process modeling software
Like AGCO power, take advantage of the benefits of process modeling and 3D simulation software.
Contact us to discuss your challenges and experience our Visual Components software during a free personalized demo.
