It is particularly critical for electronics manufacturers to get their products to market much faster to take advantage of very short profit windows. The word “simulation” is defined as the computer-based modeling of the operation of a real-world process or system over time. With this definition in mind, it is easy to understand why simulation is ubiquitous in engineering and industrial organizations; imitating a real-world process or system that allows experts to study the process or system they are interested in within a controlled environment. With the help of Industry 4.0 and simulation tools, electronics manufacturing companies are mastering a high degree of variance, continuously shrinking batch sizes and fluctuations in order volume that are increasingly difficult to predict.
The use of simulation in manufacturing allows companies to identify manufacturing bottlenecks and highlights opportunities to increase throughput and identify cost savings opportunities. It also facilitates managing inventory levels and validating the expected performance of new or existing production lines and facilities.
This white paper describes the design and implementation of several manufacturing simulation use cases at an electronics assembly factory in Nanjing, China. This factory has six surface mount lines, a high product mix, with many variants, and some high-volume production. They also have integrated circuit (ICT) and system tests, manual assembly lines, software loading stations, box-build cells, packing and labeling, shipping and aftermarket service, and depot repair. This factory is an ideal candidate for testing the effectiveness of manufacturing simulation in an electronics manufacturing environment to optimize production.
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