TOYOTA ASSEMBLY UNIT

Sandeep Bagul

Table of Contents Introduction Definition of Simulation Procedure for manufacturing of cars in the “Toyota

Assembly Unit” Simulation Model Description Simulation Attributes Simulation Process Simulation Running Model Conclusion References

Introduction

The Automobile is the most important invention second only to electricity in the 20th century. It has changed life of man in a way unimaginable before its invention.

“The world travels on wheels” is the buzzword of the 20th century.

Definition of Simulation

A simulation is an imitation of some real thing, state of affairs, or process.

The act of simulating something generally entails representing certain key characteristics or behaviors of a selected physical or abstract system.

Procedure for manufacturing of cars in the “Toyota Assembly Unit”

The manufacturing process begins with the chassis assembly. The chassis is the skeleton of the car. It is the part on which the car is built.

Axle and tires are fitted to the chassis assembly.

In the next stage, the engine is fitted to the chassis.The engine is the power producing component of the car.

Car Part brought in the Assembly Unit

Procedure (contd…)

The Gear box is then fitted into the chassis. The gear box is the component that is used to change the speed supplied to the wheels.

The next stage involves the fitting of the radiator into the engine. The radiator helps in cooling the engine, transmitting the excess heat to the surrounding by conduction.

Procedure (contd….)

The seats are then fitted to the car in the next stage.

The battery is then fitted and electrical connections are carried out. The electrical connections connect the various components of the car to the battery

The body of the car is then fitted on the chassis.

Next Stage Seat Assembly

Procedure (contd….)

The windshield, doors, and wipers are fitted to the car along with the bonnet.

The finishing touches are carried out on the car.

The car is then sent for inspection and testing after which it is taken to the parking lot and kept ready for shipping.

The windshield, doors, and wipers are fitted to the car

Simulation model description In all there are 3 Assembly Unit Centers in the Toyota

Assembly Unit Simulation Model. These 3 Assembly Unit Model namely assembly

center1,assembly center2 and assembly center are considered as Process.

Assembly center1 comprises of Chassis,Axle & Tire,Engine,Gear Box,Radiator,Seats and Electrical Assembly.

Assembly center2 comprises of Main Body Assembly. Assembly center comprises Windshield,Wiper, Doors,Finishing and Inspection Assembly.

Simulation attributes

Work time: If the job arriving at the work station is a engine or chasis it is delayed by the duration given in the work time attribute of the seize delay release block.

Operation time: If the job arriving at the work station is a main body it is delayed by the duration given in the operation time attribute of the delay block.

Timein (time in): Denotes the time at which a job arrived in the system.

Sets

Queue set: Signifies all the queues along the main assembly line, which are sequentially visited by the job.

Resource set: Denotes all the resources along the main assembly line, which are sequentially attended by the job.

In this Model Assembly press1,Assembly press2 and Assembly press are named as resources.

Variables

Every job is seize delayed and is released at the work station for a specific duration. This is obtained by fitting the historical data in the input analyzer. In the manufacturing model case the duration of delay is LOGNORMAL with a mean and standard deviation. Since there are three different types of jobs with different delays, a variable array is defined with constants for the continuous distribution. Each constant in the array signifies a part of the operand for a specific job in the delay block.

Inputs: Triangular distribution with processing time for Assembly centers.

S No Minimum (hr) Mean (hr) Maximum (hr)

1 4 7 10

2 5 8 10

3 7 9 10

Inter Arrival time:Log Normal Distribution (hrs): Log mean -15.8Log Standard deviation- 1.2

Simulation Run Starts

We simulate the model to run for 960 hrs.(i.e.,40 days) and 1 replications.

During the run the part passes through Assembly center1,Assembly center2,Assembly center and the car is ready to dispatch outside the model system.

Simulation Run Results

Run Result Average

System Number Out 61

Time Total Time (Hrs)

23.70

Entity Number In 62

Entity Number Out 61

Conclusion We get level of details such as Total estimated Time, Number of parts in the Assembly line, Processing Time,

Total production Output, Product Validation & Testing and Machine efficiency from the simulation.

Since we got the production of 61 cars in 40 days.Toyota company can alot parking lot space in the unit well in advance.

Moreover, how many workforce is required in daily shifts can be estimated through this simulation.

Usage of Assembly centers, in other words, efficiency of assembly line in manufacturing of car can also be determined from this simulation.

References

http://en.wikipedia.org/wiki/Simulation http://images.google.com/images?q=

toyota+car+assembly&svnum=10&um=1&hl=en&start=20&sa=N&ndsp=20

http://news.bbc.co.uk/nol/shared/spl/hi/guides/457000/457029/img/1171876713.gif

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