Research on Integrated Optimization of Design Parameters and Process Simulation for Throughput Efficiency

This thesis presents a comprehensive approach to enhance the production throughput of aluminium bumper beams, a critical component in automotive manufacturing. Using CATIA, an innovative bumper beam design was developed, focusing on simplicity of design and manufacturability. The design parameters considered included material selection, cross-sectional area optimization, and welding techniques to ensure both performance and ease of manufacturing. Transitioning to Tecnomatix Plant Simulation, a virtual environment was constructed to simulate the bumper beam production process. The simulation incorporated the identified design parameters, process routes, layout considerations, and machine arrangements to optimize throughput without inflating costs. By leveraging advanced simulation techniques, the study aimed to identify the most efficient production strategies while maintaining design integrity and minimizing resource consumption. Through systematic scenarios experimentation and analysis, the research yielded insights into the complex relationship between design decisions and manufacturing processes. The results highlight the potential for significant throughput enhancements achievable through collaborative optimization of design and production parameters. The optimization was able to achieve an increase in throughput of about 12.64% of its initial throughput. Moreover, the study underscores the importance of holistic approaches integrating design engineering with manufacturing simulation to drive continuous improvement in industrial operations. This thesis contributes to advancing automotive manufacturing practices by offering a methodology for enhancing production efficiency while preserving product quality and cost-effectiveness. The findings provide valuable guidance for engineers and practitioners seeking to optimize manufacturing processes through the use of simulation and design parameters