Simulation-based Optimization in the Automotive Industry – A Case Study on Body Shop Design
نویسندگان
چکیده
In the automotive industry, a new body shop production-line needs to be set up for almost every new car model. Due to the relatively short product life cycles, the planning process of body shops can almost be regarded as continuous. A main problem is to find an efficient layout fulfilling the desired production rate which is characterized by small buffer sizes and optimized cycle times. Often, the optimization of a new body shop is carried out manually, possibly supported by a simulation model to analyze the impact of different cycle times and buffer sizes. In this paper, we present a mathematical formulation and an automated optimization approach for this planning problem. The optimization modules, which have a direct interface to the underlying simulation model, are based on metaheuristics, such as genetic algorithms and simulated annealing. Here, the main task lies in comparing the manual body-in-white configuration with metaheuristic-based optimization approaches. For an evaluation of the potentials of our approach, a case study was carried out in collaboration with a German car manufacturer.
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