Engineering - Design - System Integration

SIMULATION

Analyze your plans in virtual reality

Simulate before new investments or modification of facilities, equipment, processes or production.

Versa Tech provides virtual operational solutions and answer ‘what-if’ scenarios to produce the most cost effective investment solution. An entire year of production can be simulated in minutes allowing the best decisions of the layouts, equipment investments and personnel requirements.

Versa Tech provides Simulation with Rockwell Automation Arena Software application.

Simulation software application provides a method of modeling a process through a set of algorithms. It allows observation of an operation through software simulation without the actual investment in the plant or physical equipment.

Simulation provides:

Evaluation of potential alternatives to determine the optimum performance
Determine the system performance based on Key Performance Indicators (KPIs)
Reduce risks of capital and resource expenditures through software testing
Evaluation of proposed process changes
Visualize Results with Animation

Analysis, Simulation & Master Planning

Project to develop the Master Plan to convert an existing vacant building into a standalone manufacturing factory for an existing product currently manufactured in several buildings at the same site.

Develop a facility floor plan layout for (100) production Work Cells to produce (200) SKUs.

Process and Equipment Analysis and Simulation

Equipment utilization
Man-power requirements
Process Time Studies
Material movement and maintenance
Security requirements
Detailed quality assessment requirements

Evaluate the Existing and New Equipment for all processes required to include:

Receiving
Machining
Finishing processes
Assembly processes
QC testing
Packing and Boxing
Material staging areas
Area for consumables
Area for lubricants

Work in progress (WIP)
Product build up areas
Process QC areas
Expediting areas
Office space requirements
Break room
Bath rooms
Aisles for both AGVs and pedestrians

Exterior photo from ANAD publication.jpg

Powertrain Transmission Facility

Project to design a new facility to develop a floor plan to provide LEAN process and equipment design and specification for a construction solicitation for an 110,000 square foot, $46MM integrated facility for the manufacture of tracked vehicle transmissions and related assets.

Analysis of legacy Shop Operating Procedures and Video Time Studies created the data for the Simulation.

Processes include; receiving, cleaning, painting, machine shop, welding, test/measurement, parts storage, transmission assembly, dynamometer testing, containerization, shipping and an IT inventory control system for over 22,000 SKUs.

The Simulation Models produced a dynamic, virtual replica of the process and operations.

The VTA Simulation Models results and benefits:

Existing operation analysis
Future state modeling
Dynamic calculation of resource efficiency
Identify inefficient operations
Dynamic calculation of asset utilization
Identify bottlenecks
Value Stream Mapping
Product mix analysis
Reduce travel time of product and people
Kanban Sizing
Scenario and response “What-if” analysis
Optimized factory layout
2D and 3D Virtual Presentations
Increase ROI on process improvement or capitalization spending