Modelling and Simulation of Crankcase Cover Manufacturing in the Automobile Industry

Abstract

The simulation creates the virtual production model which is exactly like the real environment, and it provides future insights before laying down the actual production plant layout. With the help of simulation, we can simulate the complex and costly manufacturing system without investing money physically and check the system’s real-life behavior. In this study, for the first time, the modelling and simulation of two-wheeler crankcase cover manufacturing are done with the help of Flexsim. This study deals with the development of a simulation model for crankcase cover manufacturing systems in the automobile industry. Flexsim simulation tool is used as an optimization tool for analyzing the effect of varying the number of operators and process stations on system performance using various scenarios. The results indicate that scenario 2 is best for crankcase cover manufacturing which reduces the overall idle time of all process stations and optimizes the number of Die-Casting Machines (DCM) and Vertical Milling Center (VMC). These results are useful for all industries for simulating their process or product layout.