Assignment requirements and guideline

Assignment 3 worth (50%)

Create a simulation of an automotive production line using a demonstration/trial version of

your preferred manufacturing modelling software and write a report.

Example software

ShowFlow
Simul8
Witness
Simio

Assignment 3
Process Simulation Exercise

Problem for Assignment 3

Production of an off road buggy

Frame:

Full box section chassis &

tubular roll-cage structure.

Steering: Car rack & pinion, shortened

Motor:

Laser cutting.
NC tube stock cutting
and bending

CNC metal folding.

CNC machining.

Manual welding (MIG)

Assembly

Road or Trailbike motors from

500 to 1000cc
Motorcycle Gearbox and

Transmission: Chain Drive to solid Rear

Axle
Single 'A' arm independent
Front Suspension: with coil over shocks, 350mm
travel
Single 'A' arm independent
Rear Suspension: with coil over shocks, 285mm
travel
Front & rear hydraulic disc
Brakes: brakes
Front: 22 x 8.00 x 10 on 10 x
Wheels: 5" rims. Rear: 25 x 12.5 x 9
tyres on 9 x 9" rims
Overall Length: 2700mm

Overall Width: 1700mm

Choose a sub assembly e.g. chassis, and develop a basic job

shop production layout for 100 buggies per week.
What would the layout look like for 1000 buggies per week?

Overall Height: 1400mm

Track (rear): 1430mm
Track (front): 1300mm
Wheelbase: 2000mm
Approx. Weight: 375kg
Ground Clearance: Adjustable to 300mm

What is the value stream map and how could it be improved?

Top Speed: 120-150kph

Acceleration: 0-100kph in 5.5 seconds

Is there another method (materials and process) that would be

more efficient to manufacture?

Complete Buggy

Chassis Parts

Chassis Material Size & Type