Case Study

Designing factory layout and optimising efficiency in aerospace manufacturing

The customer

The Customer has specialised in the design, development and production of aircraft wing leading edges, which comprise its main market. The company also specialises in wing panels and fuselage sections. In addition, The Customer is active in two very specific areas: space activities and so-called defence activities through unmanned air vehicles.

The project

The Customer asked AMIA Consulting to propose a new layout of the production unit manufacturing small sheet-metal parts and, benchmark his ‘as-is’ situation against alternative factory layouts.

The solution

The new layouts have been produced with SIMOGGA LD™, a graphical material’ handling system enabling engineers to optimise a factory layout based on a global flow analysis using a small amount of data. SIMOGGA™ optimised the functional layouts by converting them into working cells or departments. A quasi-automatic identification of product families has been highlighted as well as machines suffering under and over-capacity.

The results

A new factory layout better distributing the finishing as well as the small machining operations. A reduction of ±40% of the flows has been proposed.

Analysis of the product families have shown that the workload to manage product families could be reduced by ±90%; Design of Value Stream Mapping or Spaghetti diagrams was made for more than 2000+ product families while 80% of the flows were made by only 6 product families.

AMIA Systems

AMIA Systems is a spin-off from the "Université Libre de Bruxelles" who is developing software allowing engineers to optimise a factory layout based on a global flow analysis using few amount of data.

AMIA Consulting

AMIA Consulting is a spin-off from the "Université Libre de Bruxelles" who’s driving mission is to “work collaboratively” with his customers to deliver open solutions implementing material flow optimisation by utilising Cellular Manufacturing methods, key enabler of increased production velocity and flexibility while reducing the capital requirements