Carrier skid design for multi-model vehicle bodies: experimental and numerical insights

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Purpose This study aims to redesign and optimize production skids in an automobile factory’s paint shop to enhance productivity and efficiency within a lean manufacturing framework. By accommodating all vehicle types on a single skid design, the research seeks to minimize production time, reduce costs and improve operational reliability through total productive maintenance (TPM). The solution is robust in terms of its scalability to multiple vehicle models, significant cost savings and marked improvements in operational performance. The study also explores the effects of skid design and pallet rigidity on manufacturing line performance, providing a robust solution to streamline the production process while addressing key challenges in automotive manufacturing. Design/methodology/approach The study uses a comprehensive methodology, combining numerical analysis (finite element analysis, [FEA]) and experimental validation, to redesign production skids for accommodating multiple vehicle types. Annual production data was analyzed to identify commonalities among car bodies for skid optimization. Lean principles – particularly Kaizen and TPM – uniquely influenced the redesign by emphasizing waste elimination, continuous improvement and equipment reliability. After conceptual design, FEA was used to evaluate skid rigidity under gravity loads for different pallet configurations (flexible vs. rigid). Virtual positioning of car models on design-verified skids preceded the fabrication and implementation of skids on the production line. Maintenance strategies included replacing worn-out components to ensure seamless operations. Numerical validation assessed the impact of pallet rigidity on skid deformations, enhancing the reliability of the proposed designs in a real-world manufacturing environment. Findings The optimized skid design successfully accommodated all vehicle types, reducing the number of skids, production time and costs. Efficiency gains included a 44% reduction in downtime and a 47% decrease in production line stops. Numerical analysis confirmed the significance of pallet rigidity in minimizing skid deformations, validating the redesign approach. In addition, eliminating a low-production car model further streamlined the process. A cost-benefit discussion showed that phasing out this model freed up skid capacity and reduced operational complexity, resulting in net savings. The integration of lean manufacturing principles and TPM demonstrated significant improvements in operational efficiency, offering a scalable framework for enhancing productivity in automotive manufacturing. Originality/value This study presents a novel approach to optimizing production skids for lean automotive manufacturing. By integrating numerical analysis, experimental validation and maintenance strategies, the research offers an innovative solution to common industry challenges, such as accommodating diverse vehicle types and reducing operational inefficiencies. Unlike previous studies that focus on single-vehicle fixtures, this work addresses a multimodel skid solution under a TPM-maintained environment. The findings emphasize the importance of considering pallet rigidity in skid design and demonstrate the practical benefits of eliminating low-production models. These insights provide valuable guidance for manufacturers seeking to enhance production line reliability, reduce costs and maintain a competitive edge in the automotive industry.