Wärtsilä

The challenge: A novel product needs to be manufactured in the midst of existing operations while avoiding production collisions

Wärtsilä’s Delivery Center Vaasa faced a new challenge. Due to increase in customer volumes, a new product of different structure had to be added to production.

Over the years, Wärtsilä has co-operated with Pinja on a number of different projects. Rami Hakala, Development Manager of the Smart Manufacturing & Innovations unit of Delivery Center Vaasa, turned to the familiar partner. Pinja assisted in simulation of the company’s new production model and anticipation of potential problems.

The solution: A simulation project implemented with Pinja prevented production bottlenecks and ensured a controlled introduction of the new product

– Simulation helped us with planning of the changes in production. The simulation project gave us a chance to confirm the assumptions we had made beforehand, but potential bottlenecks were also identified in other parts of the process besides those we had originally considered, Hakala says.

– We chose Pinja as our partner because of their solid references on the implementation of simulation projects and of the excellent competence of their personnel. Once again, Pinja stayed well on top of things and the project was carried out in a controlled manner. Pinja’s process for simulation project implementation was clear, and they coached us properly as the process progressed, Hakala says.

The year-long project involved a lot of work

In all, the project lasted about a year, with 4-5 months of hard, active joint work. The project was challenging because the process simulated was extensive and included a number of interfaces in its different stages. In addition, not all of the required input data were available by the definition stage. In Hakala’s opinion, however, the project proceeded well and in a controlled manner, and almost without unforeseen difficulties.

Transfer from guessing to fact-based anticipation

In case of production changes, preparatory work is facilitated by precise simulation developed for that specific purpose. It allows basing decisions on fact-based predictions made proceeding from collected source information and verified data, rather than on guesses.

– In our case, the need for anticipation was increased by that in the future, flexible series production of two products in parallel had to be possible, both of which in large quantities. By simulating the situation during the transition period, we were able to optimize the production control parameters efficiently before implementing the actual changes, Hakala says.

The simulation project was a suitably sized package for Wärtsilä, with low risks and much to gain.

– Such projects always bring some benefits in the long term as well. The impacts of the various process elements on the big picture become specific and visualized. Identification of things worth investing in and of the most efficient way for resource allocation generates valuable knowledge, Hakala continues.

Towards smart and digital ecosystems

Anticipation will remain in need at Wärtsilä. The company is building a new Smart Technology Hub center for research, product development, and production purposes at Vaskiluoto, Vaasa. The aim is to make testing and product development more agile and efficient, and to invite other actors in the field to cooperate.

As part of the Smart Technology Hub, Wärtsilä is also developing a smart partner campus where research and product development will be carried out in co-operation with Wärtsilä’s customers and partners, start-ups in the field, and universities. The company’s philosophy places increasingly greater emphasis on partnerships, ecosystems, and co- development.

– This is a big step for us. The Smart Technology Hub can genuinely be called a technology hub of the next generation. It is strongly based on digitalization and a networked operation model. At Wärtsilä, we also want to consider the environment, not only in our operations, but also in the solutions we offer to our customers. The world needs renewable, clean energy production and flexible solutions, now more than ever, Hakala states.

From 2021, all Wärtsilä’s operations and employees in central Vaasa, as well as service workshop operations in Runsor, will be transferred to the new Hub.

– STH Smart Technology Hub leads our business towards the future. Our operations are increasingly shifting towards finding solutions in co-operation with the customer, and it is important for us to support, for example, the diverse technical solutions of our end customers. This is supported by investment into co-creation, based on partnerships beneficial for all. Our long cooperation with Pinja strongly serves the goals of working together and creating a streamlined operating model.