Generic proposals to increase productivity using discrete-event simulation for Ford Motor Company

The research project was carried out in conjunction with Ford Motor Company and Cranfield University. This research project has demonstrated partial fulfilment of the requirements for the Master Degree of Science. The project uses discrete simulation techniques to carry out experimentation with an aim of developing generic solutions to increase productivity and output of manufacturing transfer lines within the Ford group. In this highly competitive era for manufacturing where the profit margins tighten each year, Ford and other automotive companies are striving to ensure they produce products that are not only desirable to the consumer but also profitable. Every year senior management at Ford expect an increase in output for each line. This means that investigations must be carried out using simulation to formulate generic ideas and proposals to optimise and increase the output of a number of machining lines. Increasing manufacturing outputs reduces the unit cost per part; therefore there is an increase on the profit margin for each unit sold. Based on the experimental data collected from the research project, three manufacturing lines have been optimised to maximise their productivity. The solutions were then developed into business cases which were produced in line with Ford’s strict investment criteria and as a result each of the three lines should have its annual output increased by more than 5%, with a pay back period of under a year for the required capital investment. A generic solution was found which can potentially optimise any manufacturing line in the Ford Motor Company, providing large increases in annual output to Ford’s manufacturing lines. These solutions will help Ford to maximise its profit contribution per unit sold, securing its place as a leading global automotive manufacturer.