Batteries for Nissan's zero-emission LEAF car, due to start production in four newly optimized manufacturing plants including Smyrna, Tenn next year, benefit from Lanner simulation technology. Estimated Savings of up to $15 million are forecast.

Houston, TX -- (SBWire) --05/11/2011 --Nissan Motor Manufacturing UK's Sunderland plant has used Lanner process optimization and simulation software to validate production levels at their new LEAF battery facility in Sunderland, UK, and will deliver an estimated cost saving of just under $15 million once manufacturing is rolled out to three other LEAF battery plants scheduled for the US, France and Portugal.

Bob Scurr, lead engineer at Nissan Motor Manufacturing (UK), said that the project team used Lanner's WITNESS simulation software to model operational efficiency and scrap rates against the three key stages of production, including manufacturing of 12 million cells for 60,000 battery packs, linking and charging anodes, cathodes and electrolytes, and battery pack assembly.

Scurr explained that the engineering team had to rely on plant modelling to test and validate their design ideas, because of the sheer complexity of scoping out the best layout.

With the model in place, he said it mapped and analyzed the entire spectrum of production variables, facilitated an understanding of the relationships between processes at multiple stages, and tested different layouts to find the optimal approach.

"Having this model meant that the team could not only provide a watertight assurance that our Sunderland plant could cope with the volumes, but that it could do so at a substantially reduced cost base - one that was far greater than we'd hoped," commented Scurr.

Explaining that the model indicated throughput could be achieved with an investment cost saving of $3.7 million (EUR2.5m) for the Sunderland plant alone, he said that when the optimized layout is extended to the three additional battery plants planned for Portugal, France and at Smyrna, Tenn. in the US, savings would increase to over $15 million (EUR10m).

"Simulation was the only way to provide a scientific, risk free business case that would optimize the layout and identify the most efficient and productive layout for battery production," concluded Scurr.

Read the full case study "Lanner Optimizes Nissan LEAF Battery Production" click here: http://ow.ly/4IFfx

About Lanner
Any business can use the proven simulation software and services delivered by Lanner to maximize its performance and optimize its use of resources. Lanner is an international company with headquarters in the UK. Its simulation software has delivered answers for commercial businesses and government organizations since 1979, helping them move toward operational perfection. nner's customers include some of the largest and most successful organizations in the world and its technology is embedded within leading software vendors' products. For more information, visit http://www.lanner.com or follow @WitnessSim on Twitter.