Corus uses Quest to simulate breakdowns and analyse bottlenecks

Corus Engineering Steels, the Yorkshire-based steel manufacturer, has been using discrete event simulation software from Delmia to model an entire production line. Last year Corus approached Amtri, a specialist manufacturing consultancy, to create the optimum manufacturing methods, machine tools and operational sequences to produce automotive axles through its plant. Amtri used Delmia’s Quest software to design a methodology new to established axle suppliers. Ken Barrass, business development manager for Corus, explained: “We can fine tune the quality of the steel needed for a particular purpose, thus giving us a distinct advantage over other first and second tier automotive suppliers. Branching out from steel manufacture to manufacturing in steel will add value to our core product. “We considered both forging the part in one piece or friction welding. We quickly realised that each stage of the process threw up several “what ifs” and we needed help to build a fully automated, lights out, fully costed, workable solution.” To validate the various permutations, Amtri modelled the system in Quest discrete event simulation software using CAD data supplied by the machine manufacturers, who provided process cycle times, normal methods of loading and unloading, tool change and maintenance requirements. Next, the machines were laid out to a feasible floor plan, taking into account operator access, machine connectivity and machine redundancy. The logic of interconnecting conveyor and transport elements were then added, together with their characteristics and associated parts, such as buffers. Subsequently, the model was extended to include some tool changing, labour requirements and input pallet buffering, as well as rudimentary forklift requirements. It was then possible to simulate breakdowns and analyse bottleneck build-up. “For example, we analysed both fixed coil induction heating and moving coil induction heating. We were able to prove that the moving coil method was both faster and cheaper. Using it changed the whole process, which is the luxury you have when you start from first principles. Just as importantly, Quest is a communication tool, making it easy for everyone involved to understand what’s being considered and why … We were able to identify the one shift a week that required four men to change the friction welding tools. Previously, it had been assumed that four men would always be needed.”