AGV/AMR Simulation for Hot Test at Cummins JEP

Overview

JEP utilizes a Savant AGV system to transport engines from the assembly line to test cells. The Savant AGV system was put into operation in 2008. Currently, Savant has seized production for the parts necessary to repair the AGVs. Due to Savant siezing production of parts, AGVs are down for long periods of time due to lack of parts

Objectives

The main objective in the project is to create a AGV specification sheet for JEP to give to a third-party manufacturer of AGVs. To accomplish this, the team needs to create a simulation of the current hottest. In doing so, the team will be able to define the optimal specifications for the AGVs.

Approach

• The team began the project by visiting Cummins JEP to create a list of customer needs.
• Time studies and value/non-value add analysis were carried out to analyze the current system.
• A root cause analysis was conducted to investigate the biggest problem with the AGV fleet.
• The team generated seven different concepts based on the root cause analysis.
• The concept chosen was to have Cummins purchase a new AGV fleet.
• A PFMEA was conducted to find the potential failures of introducing the new AGV fleet.
• Data analysis of three month historical was conducted to find the statistical distributions of engine test times.
• A simulation was created in FlexSim to simulate the current hot test facility.
• The simulation was then verified and validated to obtain accurate simulation results.
• The simulation results were then analyzed and plotted in Excel.
• A AGV specification report was then generated and delivered for Cummins JEP

Outcomes

• Based on the results of the simulation, the team recommends that JEP purchases 5 AGVs.
• 5 AGVs will yield the same throughput as the current system which utilizes 7 AGVs.
• Cummins JEP will save $310,000 by purchasing 5 AGVs instead of 7 AGVs.
• Charging stations by each test cell and parking spot is also recommended to reduce down time of AGVs.