case study

Completing large-scale orders efficiently and on time and improving project profitability by 65 percent

MASMEC uses Plant Simulation and virtual reality integration to optimize automotive manufacturing and logistics

MASMEC uses Plant Simulation and virtual reality integration to optimize automotive manufacturing and logistics

MASMEC

MASMEC, an Italian company with over 35 years of experience in process optimization and automation, stands out for its innovation and commitment to research and development.

https://www.masmec.com/

Headquarters:
Modugno, Italy
Products:
Plant Simulation

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Thanks to the analyses in Plant Simulation and the integration of VR tools, we achieved significant improvements in production times and resource utilization compared to traditional methods."
Antonio Marinaro, Supervisor, MASMEC

Achieving a high level of efficiency

MASMEC, an Italian company with over 35 years of experience in process optimization and automation located in Modugno, stands out for its innovation and commitment to research and development (R&D). In the automotive sector, the company designs and builds production and testing systems, including assembly lines, test benches and automation systems used in manufacturing and testing vehicle components such as engines, batteries, transmissions and electronic systems.

MASMEC also expands its expertise into medical technology, offering innovative solutions for precision diagnostics, laboratory automation and surgery. With such a broad range of expertise, combined with strong connections in academia, industry and research, MASMEC is a trusted partner for cutting-edge approaches that enhance efficiency and improve the quality of life.

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Demanding higher efficiency

MASMEC has made major investments in its employees and machines. The 44,000-square-meter site includes 20,000 square meters of built space and has a production capacity of €100 million. Additionally, over 300 employees work at the site, many of them highly qualified, with nearly half holding a master’s degree or higher.

At this location, MASMEC develops tailor-made automation solutions, focusing on assembling and testing automotive components primarily used in hybrid and electric vehicles (EVs). Their offerings range from comprehensive production lines for complex manufacturing processes to end-of-line (EoL) testing machines. The company’s clients include nearly all major automotive suppliers.

However, these investments in workers and equipment requires cutting-edge automation and simulation technologies to achieve maximum efficiency.

For this, MASMEC uses Plant Simulation in the Tecnomatix® portfolio, which is part of the Siemens Xcelerator business platform of software, hardware and services.

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Harnessing the power of a digital twin

Digitalization is a key strategic priority for MASMEC, leading to the creation of a dedicated department reporting directly to the chief executive officer (CEO). Antonio Marinaro, the supervisor of the digital twin technology process at MASMEC, oversees implementing client requests.

“We use digital technologies from the start of every project,” says Marinaro. “Using a digital twin, for example, via Plant Simulation, allows us to simulate system performance in advance. Virtual and augmented reality help us collaborate with clients, ensuring mutual understanding, and we also use these tools for training and maintenance. We continually leverage industrial internet of things technology to monitor machine operations in real time. This helps us support our clients’ digital transformation journey while providing consulting services to enhance their processes.”

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Tackling a large scale order

MASMEC’s mastery of simulation technology became critical during a challenging large-scale order. Typically, MASMEC delivers individual cells or production sections, but this time, the task was to supply a production line consisting of 50 standard machines in three configurations.

“We had to manage our resources carefully, accounting for factors like material availability, personnel capacity, safety and ergonomics while simultaneously meeting strict client requirements like guaranteed costs, defined quality and a delivery time-line of just 21 weeks, which was previously only feasible for smaller deliveries,” says Marinaro.

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Using Plant Simulation to lay a foundation

To meet this demanding target, Marinaro immediately deployed simulation tools. “We created a model in Plant Simulation to manage the production phase efficiently,” says Marinaro. “This gave us an early visual representation of the processes, helping us streamline management by saving time and enabling optimal workforce planning. The model considered various material delivery schedules, resource utilization and the required delivery dates for the machines. We ran two simulation scenarios: the first optimized the logistics cadence through a milk run analysis, and the second created a project Gantt chart, aligning production activities and timelines with our production planning.”

Optimizing logistics with a milk run analysis

After completing the milk run analysis, MASMEC identified the milk run stop locations and the frequency of runs, originating from the central warehouse. It covered the machine assembly area and two connected lines for fault control and commissioning, with the central warehouse situated between them. Additionally, the company could view the working hours and distances operators needed to travel to optimize milk run stops, reducing operator strain and allowing them to focus more on their core tasks.

MASMEC divided the machine assembly area into four sections. In the first section, they built the base and upper structure of the machine. In the second, they assembled the equipment, and in the third area, they combined the upper and lower structures along with the assembled equipment. After completing the mechanical assembly, the process moved to the fourth section, where they added the electrical wiring and pneumatic piping.

Thanks to simulation insights, MASMEC organized the areas and workflows, and operators could stay on track. “By accounting for material delivery dates, assembly times for each phase and process requirements, we could compare real-world processes with the simulations daily,” says Marinaro.

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Benefiting from combining VR and simulation

As experts in digital engineering, MASMEC uses VR technology during consultations and presentations to visualize planned production environments. In tandem with Plant Simulation, the company’s experience in VR also played a key role in executing the large-scale order. MASMEC’s time and process specialists could examine assembly workflows during the design phase using VR, determining the necessary space for machine production while considering ergonomics and safety. For instance, they could leverage the VR simulation to display operator hand movements in color-coded zones around the machines. A shift in color from green to yellow to red indicated critical areas.

Improving project profitability

Despite lacking experience working at such a scale, MASMEC successfully completed the large-scale project. The simulation results were highly reliable and exceeded expectations.

“Thanks to the analyses in Plant Simulation and the integration of VR tools, we achieved significant improvements in production times and resource utilization compared to traditional methods,” says Marinaro. “With Plant Simulation, not only did we meet our target, but we also exceeded it. The expected overall project profitability was 40 percent, but we reached 65 percent. This highlights the transformative power of simulation and virtual reality in optimizing automotive manufacturing processes, boosting efficiency and competitiveness in the industry.”

With Plant Simulation, not only did we meet our target, but we also exceeded it. The expected overall project profitability was 40 percent, but we reached 65 percent.”
Antonio Marinaro, Supervisor, MASMEC