CHALLENGE

Planning the merger of two industrial plants, considering the layout, e quipment and productive processes needed to make viable the unification of the factory units into a single plant. Use of simulation tool for prior assessment of the capacity and prerequisites for operating within an optimized production concept that encompasses the innovation principles of Manufacturing 4.0 production processes and technologies.

DEVELOPMENT

During development of the layout to unify the processes of the two industrial plants, activities to characterize the particularities of the existing processes were conducted, and visits for recognition and application of diagnostic tools were carried out in the area of factory integration. The goal of the application of the tools was to analyze a process flowchart, each unit’s productive capacity, the number and features of machines and equipment, the best practices at each unit, as well as areas occupied with stock and processes. Scenario proposals were then presented enabling the evaluation of solutions for the layout and of the optimized flow for the integration of the two plants. In addition, analyses were carried out for the implementation of traceability solutions and the application of simulation systems to analyze scenarios and make decisions about investments with a focus on innovation and a Manufacturing 4.0 roadmap.

RESULT

Unification of the two Alliage units in an area of 19,000 square meters, which is half of the area previously occupied by the two units. Maintenance of a continuous, structured, lean and standardized production flow, with layout optimization and stock reduction. All of this with minimal investment in expansion and with guidance for the better use of existing equipment and infrastructure. In the technological analysis of the procedures, the Factory 4.0 concept and a pilot application of industrial traceability were developed.

The simulation stage made it possible to know in advance, with a high degree of assurance, the solutions proposed for the Alliage Factory 4.0 , allowing for fact and data-based decision-making before effectively realizing investment and implementation.