Cosworth has selected Lanner’s Witness software to support the design of a new center of excellence for production of its high performance, niche volume engines for global automotive manufacturers.
The 38,000ft² facility will produce over 20,000 parts every year and is designed to take advantage of a flexible manufacturing system that will be underpinned by a fully automated production line that uses one robot.
Adopting a mixed-mode model using a highly sophisticated pallet system, Cosworth faces a huge challenge to ensure production is optimized for continuous manufacture of a mixture of parts, irrespective of equipment breakdowns and pallet volumes.
In addressing this challenge, Cosworth – in collaboration with Cranfield University in Bedfordshire in the UK and Advanced Manufacturing Supply Chain Initiative (AMSCI) – selected the software to model the factory design and test different configurations. Crucially, the Witness model will support decision-making as the project progresses with a view to selecting the optimum design for the flexible manufacturing model. In turn this means the design can be expedited, and decisions are easier to agree on and move forward with. Through demonstrating a range of options, the model helps to optimize processes across both the factory and Cosworth’s supply chain in order to meet stringent KPIs.
Working with both Lanner and Cranfield University, Cosworth created the model to simulate the impact of numerous variables – from machinery breakdowns and different product mixes, to ascertain the most efficient, fastest route to meeting customer demand. Through simulating operational performance on a daily basis, the model highlights constraints and bottlenecks to point to the best possible outcome.
May 12, 2016