Simulation to save Nissan €10m on LEAF battery production

Bob Scurr, lead engineer at Nissan Motor Manufacturing (UK), says that the project team used Lanner's Witness simulation software to model operational efficiency and scrap rates against the three key stages of production, including manufacturing of 12 million cells for 60,000 battery packs, linking and charging anodes, cathodes and electrolytes, and finally battery pack assembly. Scurr explains that the engineering team had to rely on plant modelling to test and validate their design ideas, because of the sheer complexity of scoping out the best layout. With the model in place, he says it mapped and analysed the entire spectrum of production variables, facilitated an understanding of the relationships between processes at multiple stages, and tested different layouts to find the optimal approach. "Having this model meant that the team could not only provide a watertight assurance that our Sunderland plant could cope with the volumes, but that it could do so at a substantially reduced cost base – one that was far greater than we'd hoped," comments Scurr. Explaining that the model indicated throughput could be achieved with an investment cost saving of €2.5 million for the Sunderland plant alone, he says that when the optimised layout is extended to the three additional battery plants planned for Portugal, France and the US, it savings will increase to over €10 million. "Simulation was the only way to provide a scientific, risk free business case that would optimise the layout and identify the most efficient and productive layout for battery production," says Scurr.