A Refurbishing Factory of the Future

Context

Our client Modernizes Its Giant Refurbishing Factory to Make It the Factory of the Future

Critical business background included the following points:

• The bogies - metros' train understructure - are disassembled, cleaned, rectified, and reassembled in a factory every ten years.

• The existing lighthouse factory was built in the 30s with no significant refurbishment since then.

• The modernization has ambitious objectives, including doubling the production of bogies and handling new generation metro bogies. As a consequence, the design of the plant needs to be completely reviewed

• A first simulation of the new factory has been conducted by a major engineering company with unsatisfactory results.

Our Solutions

Deployment of DispoX

Dillygence created a custom simulation tool to validate the new design of the factory, and the mission also enabled the following:

• Centralization of the data to ease access

• Design of a flow chart of the whole factory to ease understanding of the overall process - expected to be used in the training of new employees

• Identification of blocking points, testing of different scenarios, and suggestions of improvements to be conducted

Benefits

Benefits for Deploying DispoX: Productivity Improved and Inventory Decreased

Dillygence experts used DispoX to deliver the following results:

• Identification of actions to be implemented to optimize a blocking workstation

• Determination of the need to have flexible operators pool to reach target production without additional investment

• Improvement of the productivity of the factory

• Drastic reduction of the overall inventory

The targets set were exceeded. The very convincing results of the approach led to introduce Dillygence's practice into their standard approach to designing a new plant.