Chassis Brake

Success Story in the Automotive Sector

Production and Inner Logistics Simulations

Chassis Brakes International develops and manufactures innovative braking systems with all the necessary solutions for the global automotive industry. The company has a wide range of products including state-of-the-art disc, drum, and automatic parking brakes. It offers experienced and highly qualified workforce in all areas of product and application engineering.

Chassis Brakes International - Turkey is part of the Chassis Brakes International Group, one of the largest automotive foundation brake and brake parts manufacturers in the world. The Turkey factory, located on a 20,000 square meter area in Bursa, directly supplies disk brakes, drum brakes, and automatic parking brakes to automotive OEMs and various aftermarket channels with over 300 employees.

Why were projects needed?

We wanted to consult with a simulation to feasibility of a project we thought could improve efficiency in our factory's internal logistics flows. We had problems such as imbalanced work distribution and short line stops due to the inability to feed materials on time in a busy line schedule. Seeing these losses as crucial points that need to be addressed in the production system, we started looking for a project.

We reached out to Dijitalis over the internet. The references and comments on project work were very impressive. Dijitalis' ability to provide quick feedback with its experienced team and its application of similar works in other companies also influenced our choice in favor of Dijitalis.

"We understood the importance of simulation better with this project. We thank Dijitatis for their support and valuable information they provided to us. The results we obtained from the study were much higher than our expectations. We believe that Simio should be used in every field."

Altuğ Aydoğan
Supply Chain Manager

What solution was provided?

Inner Logistics Spaghetti Diagram

While some of the dedicated forklifts assigned to the lines were not working hard enough and causing line stops due to the inability to finish the job on time, others had idle capacity with low utilization rates. This imbalance was confirmed and started to be addressed with the existing condition simulation.

Instead of forklifts assigned to the lines, it was observed clearly how much savings would be achieved by creating a forklift pool when the system was operated. In the subsequent steps, the forklift pool was tested with 5 different operating principles to find the most appropriate one.

The most suitable pool logic was calculated not to meet today's conditions but to be able to work correctly with the increasing production volumes in the future. At this point, the Dijitalis team shed light on us and proved that the number would be sufficient according to the increasing production plan quantities, once again ensuring our confidence in the accuracy of the designed system.

What benefits were obtained at the end of the project?

We have not yet implemented our project. We obtained project outputs that could create much more efficiency than we thought according to the simulation results. We want to apply this benefit provided by the Dijitalis team in the most accurate way by implementing the most appropriate solution according to the simulation results. According to the simulation results, we expect a nearly 100% increase in forklift utilization rates. Thus, we plan to achieve an improvement of nearly 30% over the total forklift count.

Your final comments and recommendations to other companies?

We thank the Dijitalis team for their positive and solution-oriented approach throughout the project. They progressed with us by understanding our problems and constraints clearly. Thus, we realized that there was even more potential than the improvement we expected from the study.

  Distance Gains Achieved