DELMIA Virtual Production for Production Performance

The DELMIA Portfolio is grouped into distinct domains within manufacturing to offer solutions to enable your entire digital factory.

 

Our Domains

DELMIA- Automatic Line Balancing (ALB)
DELMIA Automatic Line Balancing enables users to balance processes in Automotive Final Assembly applications by taking into account several restrictions and by creating of geometrical assembly stations.
Product Overview
Product Highlights
Product Key Customer Benefits

Product Overview

DELMIA Automatic Line Balancing is a powerful digital technology-based tool that provides a rich array of functionality to a planner to balance processes for automotive assembly lines. DELMIA Automatic Line Balancing offers data in a visually intuitive, graphically intensive, easy-to-use manner so that the right kinds of data are available to the planner. The primary features of the tool are:

  • Automatic balancing based on a process graph and other restrictions
  • Material planning
  • Manual re-balancing with warnings based on the restrictions
  • 2D view of stations, workplaces, processes and containers
  • Several other views

DELMIA Automatic Line Balancing makes a powerful set of functionalities available to the worker. The planner uses a process precedence graph of complex assembly sequences to find the optimal balanced assembly sequence. The balancing algorithm takes into account the following restrictions:

  • Production rate
  • Assembly process precedence
  • Space required for material supply
  • Body assignment of process
  • Locking of technical stations
  • Given worker density
  • Work process height

Based on input data DELMIA Automatic Line Balancing provides an optimised balancing approach to the planner. The user interface shows a 2D display of the assembly line with its stations and the material supply zones along the line. By drag and drop the planner is able to change the balancing result. During the work the system always checks the restrictions and gives its advices to the planner.

The balancing takes also into account the space required for material support in each station. The PPR data model is visible in the linked products and containers at each process. The planner can call the assigned parts with its containers by mouse click. For material planning the containers are carrying information of number of parts, size of containers and frequency of material supply.

Product Highlights

  • Automatic balancing based on a process graph and other restrictions

  • Material planning

  • Manual re-balancing with warnings based on the restrictions

  • 2D view of stations, workplaces, processes and containers

  • Several other views

  • Automatic Balancing based on Man, Machine & Interaction
  • Material Planning Optimizations
-Outside corners to retain the existing balancing in subsequent stations
-Two new Merging modes based on Material Area & station
-Rotate Part bins of the whole line, station & material area by 90 degrees
  • Tools Planning
  • Standard Template Processes

Product Key Customer Benefits

Automatic balancing based on a process graph and other restrictions...
Based on a process precedence graph and production rate the balancing algorithm calculates a first optimised approach. The following restrictions are input into the calculation algorithm:

  • Production rate
Number of cars produced on the assembly line in the available production time per day.

  • Assembly process precedence
The assembly precedence is a graphical description (Pert Chart) of the assembly processes which describes a summary/all possible assembly sequences. The precedence graph shows which parts have to be assembled before the next assembly step can be worked out.

  • Space required for material supply
The assembly line is built up by a sequence of stations. Each station has the same length which describes the space along the station. The processes allocated in the station require parts which have to be delivered at the stations by the logistic processes. The algorithm takes into account the limited amount of space along the station.

  • Body assignment of process
The limited work space area in a station requires a detailed planning of the processes assigned to the station. To limit the overlapping of the working areas the processes are carrying a body assignment which allows the mapping of processes to working areas. This method allows that one worker is working only on the front part and an other worker at the rear part of a car in an assembly station.

  • Locking of technical stations
The algorithm takes into account, that some stations may be locked by technical equipment installed.

  • Given worker density
The balancing requires the input of maximal worker density for the stations in the assembly line.

  • Work process height
In an automotive assembly line assembly tasks have to be carried out on different levels of heights. The balancing takes into account, that the physical conditions of a given assembly line only allows processes with a given height assignment.

Material planning...
The balancing also takes into account the space required for material support in each station. The PPR data model is visible in the linked products and containers at each process. The planner can call the assigned parts with its containers by mouse click. For material planning the containers are carrying information of number of parts, size of containers and frequency of material supply. The generated data of Automatic Line Balancing can be used for logistics planning in automotive Final Assembly.

Manual re-balancing with warnings based on the restrictions...
By drag and drop the planner is able to change the given balancing result. During the work the system always checks the restrictions and gives its warnings to the planner.

2D view of stations, workplaces, processes and containers...
The user interface shows a 2D display of the assembly line with its stations and the material supply zones along the line.

Several other views...
Beside the 2D balancing view the DELMIA Automatic Line Balancing provides an excel view of the balancing result. Furthermore there a Pert Chart view is available.

Automatic Balancing Based on Man Machine and interaction...
Automatic Balancing for FAL is based on the fact that worker works in one workplace. With this functionality planners particularly PMS planners can assign one or several workers to several machines or stations. They can assign several workers to one operation.

Material Planning Optimizations...
ALB supports the placement of part bins in one or several rows. It also provides the concept of out side corners to prevent the destruction of the planning already done when the user wants to move one part bin group. There is also a functionality to rearrange material planning for single material area and for the left and right sides of the whole line. Snap function is available for easy & quick placement of part bins. Two new merging modes "Do not duplicate Part bins inside material area" and "Do not duplicate part bins inside station" are implemented to remove duplicate part bins for optimal utilization of material areas. There is also a functionality to rotate the part bins of a material area or station or of the whole line by 90 degrees.

Tools Planning...
Tools information on the process will be used by ALB to calculate the right number of tools at the right place. That means if Tool1 is required by Process1 in Station1/Workplace1 and another Tool1 is required by Process 2 in the same workplace, then ALB assigns only one tool in workplace. If the Process 2 is moved to another workplace, then a new instance of Tool1 will be created in target workplace if not already existing.

Standard Template Processes...
The planner can create non value added process like Walking, Cleaning inside ALB. He will create templates for these processes and creates the instances of these standard processes inside ALB.