Automation of CNC Machine Tending, Part Washing and EOL Testing Validated with Simulation | Case Study

The client was planning an automated production system integrating CNC machine tending, part washing and end-of-line testing. The initial concept assumed a larger pallet buffer, a more extensive handling setup, and higher implementation cost.

A key requirement was that the line should be capable of operating 24 hours a day, with a component buffer sized to secure 72 hours of autonomy under realistic production conditions.

Before moving forward, the client needed to verify whether the proposed architecture was truly justified from the operational point of view. The main questions concerned the required pallet storage capacity, the size of the component buffer for autonomous operation, and the number of robots needed to maintain flow between stations.

A key part of the concept was a robot moving on a linear track between process stations, picking the product, performing handling operations, and placing it in the next step of the process. The original concept considered two robots, but this assumption required validation.

Key questions:

• What is the optimal pallet storage size for the assumed process?
• Is the originally planned buffer oversized?
• How should the component storage be sized to secure 72 hours of autonomy?
• Can the line operate reliably 24 hours a day while accounting for 1% NOK parts?
• Are two robots really required, or can one robot on a linear track handle the process efficiently?
• How much investment cost can be reduced compared with the initial concept?

Simulation objectives:

• Verify the target architecture of the automated line
• Determine the optimal pallet magazine capacity
• Optimize the component buffer for 72-hour autonomous operation
• Validate the line’s capability for 24-hour-a-day operation
• Assess the impact of 1% NOK parts on system continuity
• Validate robot utilization across CNC, washing and EOL stations
• Identify cost-saving opportunities versus the original concept

Nextomation developed a simulation model of the automated production process covering CNC machine tending, part washing and EOL testing.

The model mapped material flow between stations, pallet circulation, buffer logic, and robot handling tasks. Special attention was given to the robot traveling on a linear track between stations, since this element was critical to the overall system concept and investment level.

The simulation made it possible to test different buffer sizes, evaluate the required pallet magazine capacity, and verify whether one robot could maintain the expected throughput and process continuity across all stations during continuous 24-hour operation.

Additional analyses included the sizing of the component magazine for 72-hour autonomy, with 1% NOK parts taken into account in the operating assumptions.

1. Verificationof pallet storage assumptions
   The simulation tested the originally assumed pallet magazine size and compared it with the actual needs of the process.
2. Optimizationof autonomy buffers
   The component storage was analyzed to ensure 72 hours of autonomous operation under realistic production conditions, including a 1% NOK rate.
3. Validationof continuous line operation
   The model verified whether the system architecture was capable of supporting 24-hour-a-day operation without unnecessary oversizing of key resources.
4. Validationof robot handling concept
   The model verified the work cycle of the robot moving on a linear track between stations, including product pickup, transfer, handling, and placement.
5. Comparisonof alternative concepts
   Different line configurations were assessed, including the initial concept with two robots and the optimized concept with a single robot.
6. Cost-orientedconcept refinement
   The simulation results were used not only to confirm feasibility, but also to reduce unnecessary capital expenditure in the final concept.

The simulation provided clear optimization conclusions and helped refine the automation concept before implementation.

Key outcomes included:

• identification of the optimal pallet magazine size: 20 pallets instead of the 40 originally assumed,
• optimization of the component storage for 72-hour autonomy, including 1% NOK parts,
• confirmation that the line concept was capable of supporting 24-hour-a-day operation,
• reduction of investment scope versus the initial concept, including one less robot and one less linear track,
• confirmation that a single robot was sufficient to handle the required operations between stations,
• lower technical and investment risk at the concept stage.

The project showed how simulation can challenge early engineering assumptions and replace oversizing with data-based decisions.

For the client, this meant:

• a smaller and more efficient pallet buffer,
• reduced hardware and integration cost,
• a leaner automation concept with lower CAPEX,
• validated readiness for continuous daily operation,
• better understanding of real system requirements,
• stronger confidence before detailed engineering and implementation.

By using simulation at the concept stage, the client was able to optimize both the technical architecture and the investment scope of the automated line.

Instead of proceeding with an oversized solution, the project team confirmed that a significantly leaner concept would meet the operational requirements, including 24-hour-a-day operation and 72-hour autonomy. The study demonstrated that simulation is not only a validation tool, but also a practical method for reducing cost, improving system design, and supporting better investment decisions in complex industrial automation projects.