Automated Production Processes Implemented by Ford Motor Corporation
Ford Motor Company's Unrelenting Journey in Manufacturing: Evolution and Simulation
The Ford Motor Company has always been a trailblazer in the realm of manufacturing, even though it doesn't own the patent for the assembly line. The company honed this concept, laying the groundwork for the manufacturing methods that dominated the 20th century.
Nowadays, vehicle production is heavily automated and technologically complex. The research and development that goes into manufacturing a new product equals, if not surpasses, the engineering involved in the vehicle itself.
Ford has relied on process modeling software for simulations since the 1980s, using it to test a new manufacturing process before product launch and to continuously improve existing ones. As John Ladbrook, Ford's European simulation technical expert, puts it, "Getting the process right in the planning stage saves us a great deal of investment."
In partnership with Lanner, a UK-based company with roots tracing back to British Leyland Motors in the '70s, Ladbrook and his team work hand in hand with Ford's manufacturing engineers to design a new process. They input data about the process into an Excel spreadsheet, which Lanner's Witness application processes, generating a two-dimensional visual simulation of the proposed production line.
The faith in these simulations has grown exponentially, with management embracing the confidence that such tools offer. As Ladbrook explains, "Management likes that it [simulation] gives them confidence that we are going to achieve our plan targets, and that it's not just a paper calculation but based on real data. They also appreciate that we uncover problems and help come up with resolutions."
This support has led to the growth of Ladbrook's simulation team, expanding from a handful of members to a team of 12 over the past five years. "There's lots of new work going on," he shares. "That's been driven by the success of our models, which are getting more realistic and more reliable."
However, the simulations are not perfect, especially when it comes to modeling new processes. "There is still room for improvement when it comes to modeling new facilities," he mentions. "Often, the models are based on historical data that doesn't get repeated, and optimistic predictions for how equipment is going to perform in the future."
As such, Ladbrook is consistently striving to incorporate more data into the simulations, with the ultimate goal of creating a comprehensive plant simulation that can be fully trusted.
While Ford Motor Company's specific use of Lanner's software isn't extensively documented, the success achieved by Ford Otosan, a joint venture between Ford Motor Company and Otosan, steers us towards the potential benefits of such technology in the automotive sector. Ford Otosan has relied on Lanner's Twinn Witness Horizon software to model and optimize their facility designs, ensuring that production targets are met and investing wisely in machinery, robotics, and workforce planning.
- The incorporation of simulation technology in the manufacturing process has been instrumental in Ford's finance management, as it provides a basis for making informed decisions about product launches and process improvements.
- The collaboration between Ford and Lanner, a UK-based technology company, has led to the development of advanced plant simulations, potentially revolutionizing the manufacturing industry by ensuring efficient use of resources and optimal production outcomes.
