Transcript Final Project.ppt

Project : Man Utilization FMS
Cell Unit 1104
DSES 6620 Spring 2002
William Harris
Problem Statement
• Planned process improvement (10X)
– Advantage
• Less Cycle Time = More Output
– Disadvantage
• Decreased tool life – more service time
• Issues
– Impact to cell operation
• Operator perceptions
• Management expectations
Use Simulation to:
• Understand existing process
• Predict effect of new process
• Guide new process insertion
Model
Distances
Mach 1 - 80 ft
Mach 2 - 100 ft
Mach 3 - 120 ft
Mach 4 -140 ft
–
–
–
Mach 5 - 10ft
Mach 6 - 30 ft
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Assumptions
Operator efficiency
Operator tasks
Ignore
• Machine breakdowns
• Shifts & breaks
Material arrival uninterrupted
Process Data
• Average Cycle Time
– Old 3.7 hours
– New 1.3 hours
• Load times
– 15, 20, or 30 minutes
• Unload times
– 10 minutes
• Tool service times
– 3, 7, 10 minutes
– 2 occurrences/operation
• Tool life
– Old 30 minutes
– New 2 to 15 minutes
• Gamma distribution
for existing cycles
• Exponential for new
• Triangular for tool
service and load times
Validation
• Existing process data
– Actual Exits
• 20 to 22 per day
– Calculated exits
• 22.5 per day
• Simulation results
– Exits
• 15 to 22 per day
– Tool Changes
• 45 to 50 per day
– Tool Changes
• 34 to 49 per day
• 41.5 average
Operator Sanity Check
Results
• Existing process
– Operator engaged 75%
– Machinery < 30%
– 23.8 exits/day
• New Process
– Operator engaged 92%
– Machinery < 20%
– 26 exits/day
Recommendations
Assign a person to service cutters
Engage an unload station