Outputs

To demonstrate the capability of using mathematical modelling tools to support the creation of a new factory specification and layout, in terms of the shop floor system capacity, layout, flow and cost.

1. Illustrate the access and usability of modelling techniques for factory planning without specialist software.
2. Create a factory specification and an associated visual layout of the proposed factory.

Development of this model was a challenging prospect as it was designed to serve as a scalable and adaptable tool able to cope with various complex scenarios associated with OSM factory operations, as well as providing a structured and practical method for factory design.

The mathematical model not only calculates quantities of equipment and labour required to support the factory demand but allows the user to visualise the layout of the factory production system to better understand and communicate to others.

Discrete Event Simulation (DES) was used to assess the dynamic nature and performance of the factory production system over time and under various conditions and constraints.

1. Illustrate how factory analysis can be carried out using a structured platform, data sets and planning approach.
2. Create a set of key performance indicators highlighting production system process, interactions and outputs.

The 2D discrete-event simulation (DES) model managed to strike a fine balance between the provision of a user-friendly data management system and the scenario testing process.

A structured data interface was developed to enable the user to control and interact with the DES model for ease of data inputs, model build, scenario runs and output results without having to use the DES software directly.

To enhance the factory visualisation by utilising CAD models, and some factory environment modelling, a 3D representation of the factory production system and shop floor was developed.

1. Illustrate how a planned and analysed factory specification can be presented as a final factory design.
2. Create a visual 3D factory representation to aid in the understanding and communication of a factory design.

The user interface used 3D CAD models to enhance the visualisation of the factory and its environment to sufficient detail ready for a full 3D architectural model and flythrough to be developed.

The real 3D DES Model aids collaborative planning of future factory designs with internal and external stakeholder. This avoids potential issues and incorporates important factors into the overall design concept.

To engage with stakeholders and demonstrate the future factory design SMG engaged Corstorphine & Wright Architects to develop a 3D Revit architectural model.

1. Illustrate a greater level of detail both within the factory unit and surrounding service areas.
2. Create an animated fly-through to bring the design to life.

Sourcing the 3D objects can be time-consuming, with some machinery suppliers not used to being asked for 3D CAD models of their equipment, and the smaller scale bespoke equipment needing to be modelled from scratch.

As well as providing a virtual reality view of the future factory design to wider stakeholders, it has also prompted positive challenges and engagement on design decisions enabling further design iterations and improvements.

The tool set and methodology developed provides the capability to build and evaluate many different production scenarios so that investment decisions can be made with deeper insight.

1. The toolset will enhance the MTC’s offering for Business and Factory Optimisation, demonstrating that it is pushing the boundaries of the technology.
2. The tool set will not just service the construction industry; it will be used across other sectors as well. This means the AIMCH project will have developed capabilities that can be exploited in traditional manufacturing industries such as Aerospace, Defence, and Automotive.

Going forward the toolset could be developed so that process and facility designs are optimised concurrently, leading to more cost effective production facilities. This will be explored beyond AIMCH.

The project has provided a number of agile and accessible tools that have been able to be used immediately.

1. Model (and remodel) scenarios quickly and without external consultant support.
2. Inform real investment decisions with a greater degree of confidence.

It highlighted, especially with DES tools, that a certain degree of experience and understanding is required to maximise the benefits of the tools.

The tools have increased the use and acceptance of simulation and modelling to assist in decision making. The ability to reuse and reconfigure the modelling for different elements will ensure continued value.