Aston Dynamics

Monash Automation is working with Aston Dynamics and Deutsche Hydrapro to explore how automation can support the next generation of their manufacturing operations, with the commissioning of a new plant in Bendigo, Victoria. The project focuses on improving the movement and coordination of products through the key production stages while keeping the flexibility needed for operator-driven work, as rapidly growing demand raises output requirements.

Using Visual Components, the team has been simulating current and new factory layouts to visualise and identify bottlenecks and ways to improve workflow. Simulation lets ideas be tested before committing to a physical system, with a digital model of the proposed line used to investigate product flow, workstation utilisation, queueing, buffer capacity and throughput under different operating conditions.

By changing layouts, timings and control strategies virtually, the team compares design alternatives early and gets quantitative evidence for decisions, reducing reliance on trial and error during implementation.

Before selecting hardware, the team approached the problem as a production system: mapping workflows, workstation interactions, processing times, operator requirements and potential bottlenecks by working with operators and visiting the site.

From that analysis the team is developing a modular material-handling architecture that coordinates movement between stages without forcing every workstation to run at the same rate. It treats buffering, product tracking, sensing, controls, safety and operator interaction as parts of one integrated system, applying lean manufacturing principles to streamline production of hydraulic brakes and demonstrating proof of concept, modularity and extensibility.