- By Lanner
- In Customer Stories
- Posted 15/04/2016
APPLICATION:
Process Configuration | VERTICAL:
Paint & Pre-Treatment Processes | SECTOR:
Automotive
BENEFIT:
Through working with Studio Zeta and WITNESS, GEICO was able to quickly develop simulation models based on the customers’ requirements, enabling them to configure their J-Jump handling system to the exact needs of each customer.
GEICO S.p.A. based in Cinisello Balsamo, near Milan, is a
company that has a great industrial heritage as a leader
in providing turn-key coating plants for car manufacturers
worldwide.
For over half a century GEICO has worked internationally
with some of the leading car manufacturers in the
world, integrating its technology with existing systems,
modernising obsolete production lines and building new
turn-key plants.
GEICO offers solutions for all types of pre-treatment
processes, using the best technology available, to ensure
optimal treatment to prevent corrosion.
GEICO is certified by BSI (British Standards Institution)
and applies a quality management system which
complies with the requirements of ISO 9001: 2008,
with reference to the design, supply and installation of
equipment for painting and for environmental protection.
GEICO implemented a 6-Sigma quality methodology for
the pursuit of excellence in the business, focusing on
the continuous improvement of products and customer
service.
With Studio Zeta, GEICO wanted to develop a modular
simulation solution to quickly generate dynamic simulation
models based on the specific needs of its customers to
evalute the design and operation of facilities.
INTRODUCTION
The initial planning phase of the project was conducted by
GEICO alongside a selected customer, in order to verify
the feasibility of the project, identify potential problems
and optimize both technical and commercial solutions.
GEICO engineers need to certify the expected performance
of a new facility, explain how it will operate, balance
cost and performance, evaluate alternative solutions
and demonstrate how the solutions meet customer
requirements both in technical and business terms,
considering the competitive and changing worldwide
automotive market.
Customer requirements are often changing and solutions
may result in numerous combinations of possible technical
and operational solutions that require evaluation quickly.
In simple cases, where processes have few
operational steps, and where production volumes
and the product mix are predictable, traditional
analysis techniques may be sufficient. However,
as soon as operations become more complex,
the traditional approach leads inevitably to
inaccuracy and possibly to the wrong sizing of
the plant. Over sizing brings unnecessary cost
and can make the solution uncompetitive, under
sizing results due to a lack of performance and
the need for costly changes. This is why GEICO
looked to a process simulation based solution,
developed in such a way that it could become an
integral part of their engineering design projects.
Interview with Daniel Raspone - Advanced
Engineering GEICO
“When we decided to develop a method for
increasing the efficiency and effectiveness of our
operations, we looked for a solution that could
help us to respond promptly and accurately to the
demands of each customer, meeting its technical
and economical requirements, which would be
fulfi lled by our J-Jump handling system.
According to our company policy every employee
here at GEICO is a specialist in their field. To
maintain our efficiency and streamline our
processes, we have a relatively small team of
around 120 people based in Italy and we work with
many third parties, all of whom are recognized for
their excellence in their respective fields.
This helps us stay focused on our core business,
without investing resources in activities that
may be commissioned to others, who are already
recognised as leading experts in their field.
Why did we choose Studio Zeta? The answer is
simple: the solution offered by Studio Zeta, based
on the simulation software WITNESS, which is used
by many leading automotive companies, allows
us to build “pre-packaged” and parameterized
modules, which can be configured quickly, to follow
the changing demands of the customer, enabling
us to start the initial planning stage as quickly as
possible. The modules are also integrated with
Microsoft Excel, meaning that the data can be easily
used by all the people involved, even if they have no
prior technical knowledge of simulation.
So we are able to stress test quickly and accurately
the plans for our potential customer, using a
simulator, in a risk-free environment. The testing
can include both technical and commercial
parameters, providing the customer with the
assurance that their choices have undergone a
detailed analysis, demonstrating the dynamic
behaviour of the entire system accurately, rather
than being simply estimated using traditionally
based “average” performance data, which would
expose both GEICO and the pot ential customer
to technical and economic risks. This approach
has proved to be a competitive advantage for our
company.”
Objective Given to Studio Zeta
Studio Zeta were approached by GEICO to
provide pre-developed simulation modules which
could be configured on customers’ requirements,
enabling them to configure the J-Jump handling
system to the exact needs of each customers.
What is J-Jump?
GEICO’s J-Jump is a modular and flexible
transport system for pre-treatment plants and
cataphoresis (Cathodic Electro Deposition of
paint).
It is particularly suitable for medium and large
commercial vehicles, such as vans and truck
cabs. The system can handle productions of up
to 28 vehicles per hour, depending on the type of
body and of the cycle required.
The innovative concept of this handling system
is the separation of the horizontal movement of
the body during the immersion from movements
for the removal of the vehicle body, for each
individual treatment stage. This process ensures
flexibility and efficiency of the system, both in
terms of production capacity and of processing
sequence.
How the Simulator Modular Works
Using Excel, the engineer chooses the sequence
of modules that will make up the production line,
defining all its features, such as speed of the
conveyor, length, processing time etc...
The WITNESS model is able to import the data
entered in Excel and automatically build the
model of the production line, using the format
chosen by the user. Then it executes the
required simulation tests, to evaluate the chosen
options.
By using the WITNESS Quick3D feature, a 3D
navigable model can be built in a few seconds,
allowing the user to explore a real world working
model.
At the end of the simulation, the results are passed from WITNESS to Excel and shared with stakeholders.
The simulation results are a major element of
the technical report that has to be supplied
to the customer, hopefully enabling them to
select GEICO as their supplier, on the base of
the accurate data provided by the WITNESS
simulation model.
“WITNESS allows us to build “prepackaged”
and parameterized modules,
which can be configured quickly,
enabling us to start the initial planning
stage as quickly as possible.
Testing can include both technical
and commercial parameters,
providing the customer with the
assurance that their choices have
undergone a detailed analysis.”
Daniel Raspone, Advanced Engineering, GEICO