Supporting the ventilator challenge during the covid-19 pandemic with discrete event simulation modelling

Abstract

A Discrete Event Simulation (DES) model was developed by Powertrain Operations Manufacturing Engineering (PTME) in support of the Ventilator Challenge production line at a Ford Motor Company facility. The facility needed to be installed and commissioned both quickly and efficiently, with DES being one of the key tools utilised to achieve this. A flexible, dynamic input model with Excel-based data input and results dashboard enabled rapid changes to the model, enabling a clear understanding of the impact of evolving factors such as operator efficiency, labour requirements and part quality throughout the project's duration. By adopting different simulation concepts the model was applied across the entire product lifecycle, from conceptualisation to decommissioning. Through the development and implementation of this model, the characteristics of the production facility were better understood, allowing targeted engineering actions to improve productivity. This project also highlighted some key learnings for applying DES within rapidly changing manufacturing environments.