Accialini Training & Consulting provides support in Production System Design. Please visit our website www.accialiniconsulting.com or send us an email at info@accialiniconsulting.com for additional info. Please don't forget to subscribe to our newsletter!

1. Accialini Training & Consulting
Senior Consultant
Production
System Design
Nicola Accialini

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About
• As industrial competition increases, it becomes more apparent that
improved levels of output, efficiency and quality can only be
achieved by designing better production systems rather than by
merely exercising greater control over existing ones.
• The design of a production system comprises a linked set of
widely ranging activities and involves problems common to a
variety of situations, regardless of the technology and process
being used.
• Different systems are possible, but there is no one choice the best
fit to everyone: indeed, the production systems must be designed
according to specific requirements, boundaries and assumptions
to predict the market change.

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• Design new high-efficient production systems
• Improve efficiency of existing production
systems
• Reduce production costs
• Improve product quality
• Deliver on-time
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The Objectives

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The Opportunity
• Develop a bespoke production line that best fits
internal and external requirements and
boundaries;
• Combine state-of-the-art approaches and new
technologies.

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The Solution
• Implement a well-structured design approach
• Exploit new digital technologies (e.g. Discrete
Event Simulation and Virtual Reality tools) to
support the design team in the decision-
making process
• Perform a workload balance analysis
• Implement a proper layout
• Iterate the process to get the best result
possible

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Our Proposal
• ATC has developed a full work package to support your
organization.
• Based on the definition of stakeholders’ requirements, physical
boundaries (e.g. space and budget available) and company
expectations, the production sequence can be assessed by adding
more and more details.
• Once the method has been preliminary defined, then a Discrete
Event Simulation (DES) should be performed. This step is highly
recommended in any case, but especially for complex systems.
• A DES can be then used to perform a workload balance analysis as
well. If the production line is relatively simple, to cut some costs the
DES can be substituted using a structured excel file, although some
useful information will be missed.

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Our Proposal
• Next step will be the lay-out definition, which might involve
some creativity. Indeed, there is no one lay-out that fits best for
everyone, but it must be tailored for each organization. Some
examples of lay-out include:
• Flow line
• Single Routing Cell
• Multi-Routing Cell
• Process Based
• Once the sequence, method and layout has been defined and
modeled, Virtual Reality can be used to support the bought-off
of the final design. It is worth to mentioned that this is an
iterative process, and normally it takes few iteration to reach
the desired result.

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Why ATC
• ATC is able to provide the right support to your team in
designing new production systems or in improving existing
ones. ATC has collected 10+ years of experience in
developing high-quality critical modules in the aerospace
industry, more specifically accessory and power gearboxes for
aeroengines, which are probably the most critical parts of an
airplane.
• Additionally, in the past 4 years I spent most of the time in
implementing a new assembly facility for a power transmission
which is setting new standards in the aerospace industry. This
project has been developed in collaboration with research
centers in the UK, exploiting digital tools that, contrary to
popular belief, are affordable to SME.

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The Approach
• Our execution strategy incorporates proven
methodologies, extremely qualified personnel, and a
highly responsive approach to managing deliverables.
• Our execution strategy aims primarily to provide the
organization the proper support in designing new
production systems or in the improvement of existing
ones. The details of the approach will be described in the
following section.

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Requirements Definition
• The first step implies the definition of the production
system requirements like, but not limited to:
• Space availability
• Product Variation
• Max throughput
• Budget availability
• Overall Equipment Effectiveness
• In this sense, using a proper method and right tools
becomes essential to achieve the expected result.
Typically, this step can be performed remotely.

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Preliminary Project Plan
• Once the requirements have been defined and project
boundaries understood, a preliminary plan can be defined. This
will be in a form of an excel file and it will include the following
information:
• List of activities;
• Resources and required skills;
• Time schedule;
• Budget.

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Preliminary analysis of the
manufacturing/assembly sequence
• The second step implies a preliminary analysis of the
manufacturing and/or assembly steps of all the products in
the line/cell. This phase is critical, because it affects all the
downstream steps. This includes:
• Number of steps embedded in the process;
• Type of machines and/or required equipment.

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Detail definition of the
manufacturing/assembly sequence
• The fourth step is probably the most time consuming and
implies a detail definition of the overall manufacturing and/or
assembly process, including, but not limited to:
• set-up, transportation and process time;
• type and numbers of machines, fixture, tools;
• type and number of workers;
• estimated moving time between different stations;
• corrosion prevention solution (if required);
• cleaning solution;
• lifting solution;
• transportation solution;
• storing solution.

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Discrete Event Simulation
• The Discrete-Event Simulation (DES) is a very powerful tool
which is used to size and estimate key indicators.
• Key indicators are:
• max throughput;
• identify bottlenecks;
• production cost;
• lead time
• machine and workers utilization
• productivity.
• ATC will not provide a DES, but it is recommended to be
done in outsourcing, due to the both the complexity of the
topic and the software license cost. However, ATC will
support you and act as interface to speed up the process.

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Workload balance analysis
• When a DES model is available, a workload balance is
pretty straightforward.
• This analysis it is recommended to reduce the time waste
associated with inefficiencies within the line, since it is
recommended that all stations last pretty much the same
amount of time.

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Layout Definition
• Once the DES activity is completed, it is time to design the
lay-out that best fits to our requirements. This step is
typically performed in a form of a workshop. Typical
solutions include:
• Flow line
• Single Routing Cell
• Multi-Routing Cell
• Process Based
• Moreover, each solution includes different variants,
depending on specific needs.

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Process Simulation
• Process Simulation is a useful approach to analyze
important factors like:
• Ergonomics
• Space utilization
• Collision
• Fixture size
• Similar to Discrete Event Simulation, ATC will not provide
any Process Simulation, but can recommend advise the
right tool to use and be the interface with the external
provider. Additionally, it is worth to mention that Process
Simulation can be skipped in case the client doesn’t
require such level of detail.

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Virtual Build Event
• The Virtual Build Event (VBE) consists in a 1 or 2 day
workshop in which the team and stakeholders assess the
final concept by exploiting Virtual Reality capability. This
implies that the entire process has been modeled in 3D.
ATC will not provide 3D modeling, which can be done
internally or externally.
• Once the model is ready, it can be exported to be used with
Virtual Reality Equipment. ATC can recommend the most
suitable and affordable VR Kit on the market, but won’t
provide such equipment by itself.
• Recommendations from the VBE will be then implemented
in the Production System model, and a second VBE should
be taken to buy-off the final solution.

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Benefits
• Financial
• Reduce the iterations associated with production system
design
• Reduce overall costs associated with production system
design
• Reduce wastes associated to poor production system
design
• Technical
• High Quality Production System delivery

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• If you are interested, please submit these few information
and help us to tailor the service to fit best to your needs:
• Work package: How would you prefer to run the project?
• DES: Would you like to perform a DES?
• DES: Do you have any preference in terms of software?
• DES: Do you have any company preference for outsourcing?
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Request a Quotation
□No preference □Yes, use this:________________________________________
□No preference □Yes, use this:________________________________________
□Yes (recommended) □No, I don’t think I need it
□Only online □Mainly online □Mainly on-site □Only on-site

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Request a Quotation
• Company name: __________________________________
• Please send a copy of this page to the following email:
nicola@accialiniconsulting.com
• Process Simulation: Are you interested in performing a
process simulation?
• Process Simulation: If yes, what type of simulation would
you like to perform?
• Process Simulation: Do you have any preferred software?
• Process Simulation: Do you have any preferred company?
□Yes (recommended) □No, I don’t think I need it
□Ergonomics □Multiphysics □Kinematics
□No preference □Yes, use this:________________________________________
□No preference □Yes, use this:________________________________________