Automotive axle manufacture, Corus Engineering Steels, new process start-up, simulation, virtual, optimise process, prove cycle times, process proving, investment justification

Automotive Axle Manufacture

AMTRI used DELMIA's QUEST simulation software to help Corus Engineering Steels plan a new facility for the production of automotive axles. The model estrablished the optimum manufacturing methods, machine tools and operational sequences required to produce a maximum annual throughput of 700,000 units, using a methodology new to established axle maunfactureres.


	KEY RESULTS:

	- identification of best machine tools
	- proved cycle times < 30 secs achievable
	- identified fastest heating method
	- minimal manning levels determined

Double click on image to view movie
Corus Engineering Steels wanted to investigate the possibility of branching out from basic steel making to the manufacturing, in steel, of axles for the automotive industry, thus adding value to their core product. Having themsleves considered various different possible processes, they quickly realised that they needed help to answer the many "what-if" questions thrown up at each stage. AMTRI was able to draw on its long experience to convince Corus that the best process for the job would involve initial manufacture of the individual components followed by welding together (rather than trying to machine from a one-piece forging - Corus's inital idea). Next came machine selection, again eased by experience. The real challenge, however lay in the system integration as, amongst other issues, each key machine required a different method of part presentation. Fortunately QUEST provided a route to the solution. How it was done To validate the various permutations, AMTRI modelled the system in QUEST discrete event simulation software using CAD data supplied by the machine manufacturers, who also 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.
The model showed that moving coil induction heating of the components was likely to prove much faster and cheaper than using a fixed coil induction heaing system. Another key result was that only one shift of four persons per week would be needed to change the friction welding tools - Corus had initially assumed a continuous presnce would be required for this operation. One of the best attributes of the simlation, however, is its use as a communications tool, making it easy for everyone involved to understand what is being proposed and considered.

If you have an operation in your production process that might benefit from the appliaction of automation - call us.