Custom simulations for positioners: see the ROI you can achieve

Simulation technology allows you to run a detailed scenario to your product specifications for real-time production process improvements.

You’re probably familiar with the saying “a picture is worth a thousand words.” In the case of visualizing a positioner’s impact through simulation technology, one “picture” may be worth thousands of dollars in saved time and improved production processes.

ALM Positioners specializes in welding and assembly positioners to increase manufacturing productivity, safety and ergonomics. ALM is utilizing powerful simulation technology to show customers a real-life mockup of their positioners – completely customized to their process.

Positioner rendering

“Our simulation capabilities let our customers visualize exactly how ALM equipment would operate in their facility,” said Patrick Pollock, CEO and President of ALM Positioners. “It also allows them to determine cycle times and see how much time – down to the second – can be saved during welding and assembly.”

Running a detailed scenario to exact product specifications is a powerful way to visualize how to optimize production processes for improved ROI.

“It shows what the positioner does, but it also allows us to collaborate with our customers and examine their whole process,” Pollock said. “We’ll look at each cell layout and find areas that can be improved. The simulation provides a production process optimization that can bring a lot of value.”

Visualize faster throughput and safer employees.
Ensuring the safety, comfort and efficiency of skilled labor is key.
“We import our customers’ 3D model or tooling concept and show them a complete virtual workspace,” said Kevin Toft, chief revenue officer at ALM. “We can even place employees into the simulation to look at the ergonomics. We can simulate the entire line to improve material flow, storage and handling, and then optimize the process for increased efficiency and ergonomics.”
In addition to ergonomics, customers can understand how to increase safety.

“The other huge value of a simulation is understanding the safety of the operation,” Toft said. “You can literally see how the positioner and other changes to the process can make it safer for your skilled employees in real time. It’s a total ‘aha’ moment!”
A simulation is the ultimate “what if” tool, allowing customers to safely play out different scenarios and test various layouts before making a big decision. Not only can it help inform capital investments, but it can act as an educational tool for employees.

Extremely detailed, with accuracy down to inches.
Just how detailed can a simulation get? That’s up to the customer. The more data inputs, the more powerful and detailed the simulation.

“With the simulation, we’re able to bring the customers’ ideas to life in so much detail,” said Rob Doneth, process engineer at ALM. “You can talk about how a part is being moved and how it should be welded, and then when we create the simulation, we can make tweaks to improve the process. You can avoid mistakes before you even make them.”

Another bonus of the simulation? Extreme accuracy.

“When we have models of the parts and tooling, it’s very accurate,” Doneth said. “That’s huge when it comes to gaining efficiency and ensuring that the improvements are going to work as planned.”
Before a big change, a simulation reassures operators by showing them what’s to come before it’s on the floor.

“We can create videos or snapshots to show how and why changes make their floor better, safer and more efficient to gain that buy-in,” Doneth said. “Together, we can make tweaks with a few clicks to see what would happen if we shifted to a robot cell or used a different positioner. It’s the most powerful tool to transform your floor and gain efficiency.”

It all comes down to this: the ultimate reward for the ALM team is making everyone’s lives easier, safer and more efficient. The most powerful way to do that is a simulation.

Ready for a positioner to transform your assembly process? Our team and simulation technology can help. Find out if your business qualifies for a free simulation by giving us a call at (309) 787-6200 or filling out our form.

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