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