Toy Airplane Manufacturing Mini Project: Christian Mickelson Ted Pelzer Todd Madole IE 4235

Toy Airplane Manufacturing
Mini Project
Christian Mickelson
Ted Pelzer
Todd Madole
IE 4235
Case Study 1: Toy Airplane Manufacturing
A toy company produces three types (A,B and C) of a toy aluminum airplanes in the following daily
volumes: A=1000 B=1500 and C=1800. The company expects demand to increase for its products 30
percent over the next six months and needs to know the total machines, AGV’s and operators that will be
required. All planes go through five operations except for plane A, which skips the cutting operation.
Following is a list of operation times, move times and resources used:
Opn Description Operation Time Resource Move Logic
10 Die Casting 3 min (outputs 6 parts) Automated die caster.3 min
20 Cutting Triangular(.25,.28,.35) Cutter none
30 Grinding Sample Times: .23 .22 .26 .22 Grinder .2 min
.25 .23 .24 .22 .21 .23 .20 .23
.22 .25 .23 .24 .23 .25 .47 .23
.25 .21 .24 .22 .26 .23 .25 .24
.21 .24 .26
40 Coating 12 min per batch of 24 Coater .2min
50 Inspection and Packaging Triangular(.27,.30,.40) Packager exits with 88% yield
After die casting, planes are moved to each operation in batch sizes of 24. Input buffers exist at each
operation. The factory operates eight hours a day, five days per week. The factory starts out empty at the
beginning of each day and ships all parts produced at the end of the day. The die caster experiences
downtime every 30 minutes exponentially distributed and takes 8 minutes normally distributed with a
standard deviation of 2 minutes to repair. One maintenance person is always on duty to make repairs.
Model Building and Assumptions:

The .47 grinding time was ignored in the data set because it is a statistical outlier that does not fit
the rest of the data. It can be assumed that this time was caused do to some non- regular operating error.
It was also assumed that the AGVs move the appropriate speed and distances required for the given move
times. Batches consist of 24 planes of the same type. Operation times are the same for each type of plane
and any change over in tooling is also assumed in the operation time. Each machine requires at least one
operator. Additional operators would be required depending on how the company applies benefits and
break times. Each simulation model also includes a system that reorders more raw materials when 6
planes are added to scrap.
As-Is Model
First an as-is model was constructed for the facility. Initially, the team viewed operation times and found
that the die caster seemed to be a bottleneck operation. The team used Calculation 1 to find the minimum
number of machines needed to meet demand.
Deterministic Modeling:
(Assuming worst case scenario for operation times)
Cutter:
.35 min * 4300 planes = 1505 minutes required
1505 minutes/480 minutes in a day = 3.1 machines => 4 Cutting machines

Grinding:
.27 min * 4300 planes = 1161 minutes /480 minutes in a day = 2.4 => 3 Grinding machines
Coating:
3300 planes / 24 per batch = 138 batches
12min * 138 batches = 1656 minutes / 480 minutes in a day = 3.45 => 4 Coating Machines
Inspect & Package:
.4 min * 4300 planes = 1720 minutes
1720 minutes / 480 minutes in a day = 3.6 => 4 Inspect & Package stations
Die Caster:
4300 planes/6 planes per cast = 717 raw material entities to die casting
717 raw material entities * 3 minute operation time = 2151 minutes
2151min / 480 minutes in a day = 4.5 machine => 5 die casting machines needed (assuming no downtimes)
Each of the calculations does not include downtimes. This is why the calculations do not match the exact
number actually used in the simulation.
The following is a list of the equipment needed to produce the as-is quantities of toy airplanes:
Resource Quantity Average Utilization
Die Caster 8 63.67%
Cutter 4 74.49%
Grinder 3 78.47%
Coater 5 78.00%
Packager 2 82.10%
AGV 3 6.08%
Mechanic 3 42.58%
Chart 1
The die caster had to be increased to 8 units due to the high amount of downtime. The die casters were
down an average of 16.72% of the time. Each Plane A spent 12.5 minutes in the system. Plane B and
Plane C took 22.58 min and 22.22 min respectively.
An important part of this model to reduce bottle necks was how the planes arrived to the system. Since
only planes B and C went through the coating process it was best to alternate them. The group set arrivals
so that planes would arrival at 9 minute intervals. This was done because it took 3 minute per part at the
die caster so a different part arrived every 3 minutes to the system. By doing this it reduced blocking at the
coater and helped to reduce the number needed.
It was determined that the 3 AGVs needed would each travel on their own network. A comparison model
was run with 3 AGVs and one path network. One path network and three separate path networks
produced the same amount of planes during an 8 hour day. The team chose 3 separate networks to reduce
the wear and tear on the AGVs. 3 separate paths would also be safer than 1 path that traverses the whole
facility. The total area covered by the 3 separate paths would be fractional compared to 1 path. This will
also keep the AGV’s in their own zones to avoid the possibility of collisions 3 AGVs were needed
regardless of the type of path network. 2 AGVs in one path network produced 87 fewer planes than
needed. A chart of these pros and cons is listed below:
Utilization % Notes:
1-Path Network 30.40% Less safe, more area is
covered
3-Path network 8.01% More Safe, small area
covered. Also no
collisions possible
Chart 2
To-Be Model; Using specifications of Case Study
The new manufacturing system expects a 30% increase in production. More machines were added to the
system to account for the increased demand.
The chart below shows the new quantities and utilization percentages:
Resource Quantity Change Average Utilization

Die Caster 10 +2 67.12%
Cutter 5 +1 78.22%
Grinder 4 +1 77.46%
Coater 6 +1 84.89%
Packager 3 +1 71.58%
AGV 3 0 8.01%
Mechanic 3 0 63.42%
Chart 3
Two machines were added for die casting to account for the excessive downtimes. The average down time
for the die casters in the new model was 21.69%. One machine was added to each of the other processes
to keep up with the increased demand. The AGVs and mechanics remain unchanged while each of their
utilization percentages increases.
To-Be; Creative Solution
To reach 30% increase in production, the facility can easily increase the amount of machines; however the
group found many inefficiencies in the process.
If downtime occurs every 120 minutes rather than 30 minutes, the die casters can meet the new production
requirements. The group suggests that the die casters be modified to be more reliable rather than
purchasing more die casters at an increased cost.
The system only has an 88% yield. This means that 12 out of every 100 planes is a defect. Increasing the
yield to 3 sigma levels reduced the amount of scrap produced from 805 planes to 63 planes in 8 hours of
production. If the system is able to increase quality to 3 Sigma and the downtimes are reduced to every 2
hours, only 1 grinder needs to be added while the mechanics can be reduced to only 1. Chart 3 shows
required numbers for a more efficient FMS:
Resource Quantity Change Average Utilization

Die Caster 8 -2 74.30%
Cutter 4 -1 86.89%
Grinder 4 0 68.79%
Coater 5 -1 90.36%
Packager 2 -1 94.61%
AGV 3 0 7.15%
Mechanic 1 -2 42.36%
Chart 4
Conclusion:
The group suggests that the creative solution be implemented in this case study. Increasing the efficiency
of the facility will require the purchase of only 1 new grinder to keep up with demand. The increased
efficiency will also reduce the mechanics needed to only 1 reducing work force costs. It is more important
to add efficient machines that produce quality parts than to add more machines to the system to meet
demand. Reducing the overall number of machines in the facility and increasing quality will reduce
machine costs, workforce costs, material costs and WIP.
Appendix
General Report: As-Is Model Output
--------------------------------------------------------------------------------
General Report
Output from C:\DOCUME~1\mado0012\Desktop\PLANET~2.MOD
Date: Dec/05/2006 Time: 09:30:27 AM
--------------------------------------------------------------------------------
Scenario : Normal Run
Replication : 1 of 1
Simulation Time : 8 hr
--------------------------------------------------------------------------------
LOCATIONS Average
Location Scheduled Total Minutes Average Maximum Current
Name Hours Capacity Entries Per Entry Contents Contents Contents % Util
--------------- --------- -------- ------- --------- -------- -------- -------- ------
Die Casting.1 8 1 114 3.00 0.71 1 0 71.25
Die Casting.2 8 1 109 3.00 0.68 1 0 68.12
Die Casting.3 8 1 93 3.00 0.58 1 0 58.12
Die Casting.4 8 1 104 3.00 0.65 1 0 65.00
Die Casting.5 8 1 98 3.00 0.61 1 0 61.25
Die Casting.6 8 1 104 3.00 0.65 1 0 65.00
Die Casting.7 8 1 94 3.00 0.58 1 0 58.75
Die Casting.8 8 1 99 3.00 0.61 1 0 61.88
Die Casting 64 8 815 3.00 0.63 8 0 63.67
Cutting.1 8 1 1218 0.29 0.74 1 0 74.50
Cutting.2 8 1 1217 0.29 0.74 1 0 74.46
Cutting.3 8 1 1220 0.29 0.74 1 0 74.57
Cutting.4 8 1 1217 0.29 0.74 1 0 74.44
Cutting 32 4 4872 0.29 0.74 4 0 74.49
Grinder.1 8 1 1627 0.23 0.78 1 0 78.50
Grinder.2 8 1 1624 0.23 0.78 1 0 78.51
Grinder.3 8 1 1621 0.23 0.78 1 0 78.40
Grinder 24 3 4872 0.23 0.78 3 0 78.47
Coater.1 8 1 33 12.00 0.82 1 0 82.50
Coater.2 8 1 32 12.00 0.8 1 0 80.00
Coater.3 8 1 31 12.00 0.77 1 0 77.50
Coater.4 8 1 30 12.00 0.75 1 0 75.00
Coater.5 8 1 30 12.00 0.75 1 0 75.00
Coater 40 5 156 12.00 0.78 5 0 78.00
IandP.1 8 2 2436 0.32 1.64 2 0 82.16
IandP.2 8 2 2436 0.32 1.64 2 0 82.04
IandP 16 4 4872 0.32 1.64 4 0 82.10
RM storage 8 999999 815 25.12 42.66 104 0 0.0
Cutting buffer 8 999999 203 2.47 1.04 4 0 0.0
Grinding buffer 8 999999 203 2.74 1.16 3 0 0.0
Coating buffer 8 999999 156 5.07 1.64 12 0 0.0
IandPconv 8 999999 203 3.72 1.57 5 0 0.0
Batch1 8 72 4890 2.48 25.27 72 18 35.10
Batch2 8 72 4872 0.88 8.97 26 0 12.46
Batch4 8 72 4872 0.81 8.30 25 0 11.53
Scrap 8 999999 572 0.0 0 1 0 0.0
LOCATION STATES BY PERCENTAGE (Multiple Capacity)

% |
Location Scheduled % Partially % | %
Name Hours Empty Occupied Full | Down
--------------- --------- ------ --------- ----- | ----
IandP.1 8 17.58 0.51 81.90 | 0.0
IandP.2 8 17.67 0.58 81.75 | 0.0
IandP 16 17.63 0.55 81.83 | 0.0
RM storage 8 24.05 75.95 0.0 | 0.0
Cutting buffer 8 28.18 71.82 0.0 | 0.0
Grinding buffer 8 22.85 77.15 0.0 | 0.0
Coating buffer 8 70.39 29.61 0.0 | 0.0
IandPconv 8 18.82 81.18 0.0 | 0.0
Batch1 8 1.73 98.23 0.04 | 0.0
Batch2 8 25.60 74.40 0.0 | 0.0
Batch4 8 31.22 68.78 0.0 | 0.0
Scrap 8 100.00 0.0 0.0 | 0.0
LOCATION STATES BY PERCENTAGE (Single Capacity/Tanks)
Location Scheduled % % % % % %
Name Hours Operation Setup Idle Waiting Blocked Down
------------- --------- --------- ----- ----- ------- ------- -----
Die Casting.1 8 71.25 0.0 14.99 0.0 0.0 13.76
Die Casting.2 8 68.13 0.0 19.64 0.0 0.0 12.23
Die Casting.3 8 58.13 0.0 20.30 0.0 0.0 21.57
Die Casting.4 8 65.00 0.0 20.51 0.0 0.0 14.49
Die Casting.5 8 61.25 0.0 20.17 0.0 0.0 18.58
Die Casting.6 8 65.00 0.0 20.36 0.0 0.0 14.64
Die Casting.7 8 58.75 0.0 19.74 0.0 0.0 21.51
Die Casting.8 8 61.88 0.0 21.11 0.0 0.0 17.01
Die Casting 64 63.67 0.0 19.60 0.01 0.0 16.72
Cutting.1 8 74.50 0.0 25.50 0.0 0.0 0.0
Cutting.2 8 74.46 0.0 25.54 0.0 0.0 0.0
Cutting.3 8 74.57 0.0 25.43 0.0 0.0 0.0
Cutting.4 8 74.44 0.0 25.56 0.0 0.0 0.0
Cutting 32 74.49 0.0 25.51 0.0 0.0 0.0
Grinder.1 8 78.50 0.0 21.50 0.0 0.0 0.0
Grinder.2 8 78.51 0.0 21.49 0.0 0.0 0.0
Grinder.3 8 78.40 0.0 21.60 0.0 0.0 0.0
Grinder 24 78.47 0.0 21.53 0.0 0.0 0.0
Coater.1 8 82.50 0.0 17.50 0.0 0.0 0.0
Coater.2 8 80.00 0.0 20.00 0.0 0.0 0.0
Coater.3 8 77.50 0.0 22.50 0.0 0.0 0.0
Coater.4 8 75.00 0.0 25.00 0.0 0.0 0.0
Coater.5 8 75.00 0.0 25.00 0.0 0.0 0.0
Coater 40 78.00 0.0 22.00 0.0 0.0 0.0
RESOURCES
Average Average Average
Number Minutes Minutes Minutes
Resource Scheduled Of Times Per Travel Travel % Blocked
Name Units Hours Used Usage To Use To Park In Travel % Util
------------- ----- --------- -------- ------- ------- ------- --------- ------
Die to Cut 1 8 203 0.08 0.0 0.08 0.0 3.85
Grind to Coat 1 8 203 0.25 0.0 0.25 0.0 10.61
Coat to IP 1 8 156 0.11 0.0 0.11 0.0 3.77
Maitenance.1 1 8 35 7.91 0.11 0.13 0.0 58.51
Maitenance.2 1 8 28 7.24 0.11 0.13 0.0 42.95
Maitenance.3 1 8 16 7.77 0.10 0.13 0.0 26.28
Maitenance 3 24 79 7.64 0.11 0.13 0.0 42.58
RESOURCE STATES BY PERCENTAGE
% %
Resource Scheduled % Travel Travel % %
Name Hours In Use To Use To Park Idle Down
------------- --------- ------ ------ ------- ----- ----
Die to Cut 8 3.72 0.13 3.59 92.56 0.0
Grind to Coat 8 10.61 0.0 10.61 78.79 0.0
Coat to IP 8 3.77 0.0 3.77 92.46 0.0
Maitenance.1 8 57.68 0.83 0.83 40.66 0.0
Maitenance.2 8 42.28 0.67 0.67 56.39 0.0
Maitenance.3 8 25.92 0.36 0.36 73.36 0.0
Maitenance 24 41.96 0.62 0.62 56.80 0.0
FAILED ARRIVALS
Entity Location Total

Name Name Failed
------------- ---------- ------
Raw MaterialA RM storage 0
Raw MaterialB RM storage 0
Raw MaterialC RM storage 0
ENTITY ACTIVITY
Average Average Average Average Average
Current Minutes Minutes Minutes Minutes Minutes
Entity Total Quantity In In Move Wait For In
Name Exits In System System Logic Res, etc. Operation Blocked
------------- ----- --------- ------- ------- --------- --------- -------
PlaneA 1002 6 37.98 0.64 7.93 3.92 25.48
PlaneB 1495 12 57.85 0.37 6.28 15.92 35.27
PlaneC 1803 0 57.15 0.36 5.92 15.92 34.93
Raw MaterialA 0 0 - - - - -
Raw MaterialB 0 0 - - - - -
Raw MaterialC 0 0 - - - - -
Junk 572 0 51.29 0.43 6.13 13.28 31.45
ENTITY STATES BY PERCENTAGE

% %
Entity In Move Wait For % %
Name Logic Res, etc. In Operation Blocked
------------- ------- --------- ------------ -------
PlaneA 1.70 20.88 10.33 67.08
PlaneB 0.64 10.87 27.52 60.96
PlaneC 0.64 10.37 27.86 61.12
Raw MaterialA - - - -
Raw MaterialB - - - -
Raw MaterialC - - - -
Junk 0.84 11.95 25.89 61.32
General Report: To-Be Model Output

--------------------------------------------------------------------------------
General Report
Output from C:\DOCUME~1\mado0012\Desktop\PLANET~1.MOD
Date: Dec/05/2006 Time: 09:29:53 AM
--------------------------------------------------------------------------------
--------------------------------------------------------------------------------
LOCATIONS
Average
--------------- --------- -------- ------- --------- -------- -------- -------- ------
Die Casting.1 8 1 119 3.00 0.74 1 0 74.38
Die Casting.2 8 1 112 3.00 0.7 1 0 70.00
Die Casting.3 8 1 105 3.00 0.65 1 0 65.62
Die Casting.4 8 1 117 3.00 0.73 1 0 73.12
Die Casting.5 8 1 104 3.00 0.65 1 0 65.00
Die Casting.6 8 1 95 3.00 0.59 1 0 59.38
Die Casting.7 8 1 110 3.00 0.68 1 0 68.75
Die Casting.8 8 1 101 3.00 0.63 1 0 63.12
Die Casting.9 8 1 103 3.00 0.64 1 0 64.38
Die Casting.10 8 1 108 3.00 0.67 1 0 67.50
Die Casting 80 10 1074 3.00 0.67 10 0 67.12
Cutting.1 8 1 1282 0.29 0.78 1 0 78.31
Cutting.2 8 1 1283 0.29 0.78 1 0 78.08
Cutting.3 8 1 1279 0.29 0.78 1 0 78.20
Cutting.4 8 1 1279 0.29 0.78 1 0 78.17
Cutting.5 8 1 1285 0.29 0.78 1 0 78.32
Cutting 40 5 6408 0.29 0.78 5 0 78.22
Grinder.1 8 1 1602 0.23 0.77 1 0 77.33
Grinder.2 8 1 1601 0.23 0.77 1 0 77.63
Grinder.3 8 1 1602 0.23 0.77 1 0 77.30
Grinder.4 8 1 1603 0.23 0.77 1 0 77.60
Grinder 32 4 6408 0.23 0.77 4 0 77.46
Coater.1 8 1 37 12.00 0.92 1 0 92.50
Coater.2 8 1 36 11.91 0.89 1 1 89.36
Coater.3 8 1 35 12.00 0.87 1 0 87.50
Coater.4 8 1 34 12.00 0.85 1 0 85.00
Coater.5 8 1 33 12.00 0.82 1 0 82.50
Coater.6 8 1 29 12.00 0.72 1 0 72.50
Coater 48 6 204 11.98 0.84 6 1 84.89
IandP.1 8 2 2132 0.32 1.43 2 0 71.58
IandP.2 8 2 2128 0.32 1.43 2 0 71.67
IandP.3 8 2 2124 0.32 1.42 2 0 71.50
IandP 24 6 6384 0.32 1.43 6 0 71.58
RM storage 8 200 1074 42.56 95.25 178 0 47.63
Cutting buffer 8 999999 267 1.95 1.09 4 0 0.0
Grinding buffer 8 999999 267 1.23 0.68 2 0 0.0
Coating buffer 8 999999 204 7.54 3.20 17 0 0.0
IandPconv 8 999999 266 1.56 0.86 3 0 0.0
Batch1 8 72 6444 1.85 24.90 60 36 34.58
Batch2 8 72 6408 0.63 8.44 24 0 11.73
Batch4 8 72 6408 0.66 8.89 25 0 12.36
Scrap 8 999999 805 0.0 0 1 0 0.0
OCATION STATES BY PERCENTAGE (Multiple Capacity)
% |
--------------- --------- ------ --------- ----- | ----
IandP.1 8 27.26 2.32 70.42 | 0.0
IandP.2 8 27.23 2.19 70.58 | 0.0
IandP.3 8 27.36 2.28 70.36 | 0.0
IandP 24 27.28 2.27 70.45 | 0.0
RM storage 8 14.48 85.52 0.0 | 0.0
Cutting buffer 8 25.32 74.68 0.0 | 0.0
Grinding buffer 8 31.48 68.52 0.0 | 0.0
Coating buffer 8 64.00 36.00 0.0 | 0.0
IandPconv 8 33.74 66.26 0.0 | 0.0
Batch1 8 2.39 97.61 0.0 | 0.0
Batch2 8 30.97 69.03 0.0 | 0.0
Batch4 8 26.52 73.48 0.0 | 0.0
Scrap 8 100.00 0.0 0.0 | 0.0
-------------- --------- --------- ----- ----- ------- ------- -----
Die Casting.1 8 74.38 0.0 5.05 0.0 0.0 20.57
Die Casting.2 8 70.00 0.0 9.76 0.0 0.0 20.24
Die Casting.3 8 65.63 0.0 10.32 0.0 0.0 24.05
Die Casting.4 8 73.13 0.0 12.64 0.0 0.0 14.23
Die Casting.5 8 65.00 0.0 13.15 0.0 0.0 21.85
Die Casting.6 8 59.38 0.0 10.75 0.0 0.0 29.87
Die Casting.7 8 68.75 0.0 13.05 0.0 0.0 18.20
Die Casting.8 8 63.13 0.0 11.77 0.0 0.0 25.10
Die Casting.9 8 64.38 0.0 12.79 0.0 0.0 22.83
Die Casting.10 8 67.50 0.0 12.56 0.0 0.0 19.94
Die Casting 80 67.13 0.0 11.18 0.0 0.0 21.69
Cutting.1 8 78.31 0.0 21.69 0.0 0.0 0.0
Cutting.2 8 78.08 0.0 21.92 0.0 0.0 0.0
Cutting.3 8 78.20 0.0 21.80 0.0 0.0 0.0
Cutting.4 8 78.17 0.0 21.83 0.0 0.0 0.0
Cutting.5 8 78.32 0.0 21.68 0.0 0.0 0.0
Cutting 40 78.22 0.0 21.78 0.0 0.0 0.0
Grinder.1 8 77.33 0.0 22.67 0.0 0.0 0.0
Grinder.2 8 77.63 0.0 22.37 0.0 0.0 0.0
Grinder.3 8 77.30 0.0 22.70 0.0 0.0 0.0
Grinder.4 8 77.60 0.0 22.40 0.0 0.0 0.0
Grinder 32 77.46 0.0 22.54 0.0 0.0 0.0
Coater.1 8 92.50 0.0 7.50 0.0 0.0 0.0
Coater.2 8 89.36 0.0 10.64 0.0 0.0 0.0
Coater.3 8 87.50 0.0 12.50 0.0 0.0 0.0
Coater.4 8 85.00 0.0 15.00 0.0 0.0 0.0
Coater.5 8 82.50 0.0 17.50 0.0 0.0 0.0
Coater.6 8 72.50 0.0 27.50 0.0 0.0 0.0
Coater 48 84.89 0.0 15.11 0.0 0.0 0.0
RESOURCES
------------- ----- --------- -------- ------- ------- ------- --------- ------
Die to Cut 1 8 267 0.08 0.0 0.08 0.0 5.08
Grind to Coat 1 8 267 0.25 0.0 0.25 0.0 14.04
Coat to IP 1 8 203 0.11 0.0 0.11 0.0 4.91
Maitenance.1 1 8 37 8.98 0.08 0.13 0.0 69.95
Maitenance.2 1 8 37 8.81 0.07 0.13 0.0 68.56
Maitenance.3 1 8 32 7.69 0.06 0.13 0.0 51.75
Maitenance 3 24 106 8.53 0.07 0.13 0.0 63.42

% %
------------- --------- ------ ------ ------- ----- ----
Die to Cut 8 4.90 0.18 4.71 90.21 0.0
Grind to Coat 8 14.04 0.0 14.04 71.91 0.0
Coat to IP 8 4.91 0.0 4.91 90.19 0.0
Maitenance.1 8 69.29 0.67 0.67 29.38 0.0
Maitenance.2 8 67.95 0.61 0.61 30.83 0.0
Maitenance.3 8 51.31 0.44 0.44 47.81 0.0
Maitenance 24 62.85 0.57 0.57 36.01 0.0
FAILED ARRIVALS
Name Name Failed
------------- ---------- ------
ENTITY ACTIVITY

------------- ----- --------- ------- ------- --------- --------- -------
PlaneA 1325 6 49.70 0.64 5.05 3.92 40.07
PlaneB 1932 37 73.75 0.36 3.55 15.92 53.90
PlaneC 2322 18 74.13 0.37 3.62 15.92 54.22
Junk 805 0 67.56 0.43 3.73 13.13 50.26
% %
------------- ------- --------- ------------ -------
PlaneA 1.30 10.18 7.89 80.63
PlaneB 0.50 4.82 21.59 73.09
PlaneC 0.50 4.89 21.48 73.14
Junk 0.64 5.53 19.44 74.39
Formatted Listing of To-Be Model

********************************************************************************
* *
* Formatted Listing of Model: *
* C:\temp\planetrialdowntime.MOD *
* *
********************************************************************************
Time Units: Minutes

Distance Units: Feet
********************************************************************************
* Locations *
********************************************************************************
Name Cap Units Stats Rules Cost

--------------- -------- ----- ----------- --------------- ------------
Die_Casting 1 8 Time Series Oldest, , First
Die_Casting.1 1 1 Time Series Oldest, ,
Cutting 1 4 Time Series Oldest, , First
Cutting.1 1 1 Time Series Oldest, ,
Grinder 1 4 Time Series Oldest, , First
Grinder.1 1 1 Time Series Oldest, ,
Coater 1 5 Time Series Oldest, , First
Coater.1 1 1 Time Series Oldest, ,
IandP 2 2 Time Series Oldest, , First
IandP.1 2 1 Time Series Oldest, ,
IandP.2 2 1 Time Series Oldest, ,
RM_storage 500 1 Time Series Oldest, ,
Cutting_buffer inf 1 Time Series Oldest, ,
Grinding_buffer inf 1 Time Series Oldest, ,
Coating_buffer inf 1 Time Series Oldest, ,
IandPconv INFINITE 1 Time Series Oldest, FIFO,
Batch1 72 1 Time Series Oldest, ,
Scrap inf 1 Time Series Oldest, ,
********************************************************************************
* Usage downtimes for Locations *
********************************************************************************
Loc Frequency First Time Priority Logic

------------- ------------ ------------ ------------ ------------------
Die_Casting E(120) Min 99 GET 1 Maitenance
WAIT N(8, 2)
FREE Maitenance
Die_Casting.1 E(120) Min 99 GET 1 Maitenance

WAIT N(8, 2)
FREE Maitenance

WAIT N(8, 2)
FREE Maitenance

WAIT N(8, 2)
FREE Maitenance

WAIT N(8, 2)
FREE Maitenance

WAIT N(8, 2)
FREE Maitenance

WAIT N(8, 2)
FREE Maitenance

WAIT N(8, 2)
FREE Maitenance

WAIT N(8, 2)
FREE Maitenance
********************************************************************************
* Entities *
********************************************************************************
Name Speed (fpm) Stats Cost

------------- ------------ ----------- ------------
PlaneA 150 Time Series
PlaneB 150 Time Series
PlaneC 150 Time Series
Raw_MaterialA 150 Time Series
Raw_MaterialB 150 Time Series
Raw_MaterialC 150 Time Series
Junk 150 Time Series
********************************************************************************
* Path Networks *
********************************************************************************
Name Type T/S From To BI Dist/Time Speed Factor

-------- ----------- ---------------- -------- -------- ---- ---------- ------------
Path1 Passing Speed & Distance N1 N2 Bi 13.33 1
N1 N3 Bi 82.93 1
Repair Passing Speed & Distance N1 N2 Bi 19.98 1
********************************************************************************
* Interfaces *
********************************************************************************
Net Node Location

---------- ---------- --------------
Path1 N1 Batch1
N2 Cutting_buffer
Path3 N1 Batch2
N2 Coating_buffer
N3 IandPconv
Path4 N1 Coater
N2 IandPconv
Repair N2 Die_Casting
********************************************************************************
* Resources *
********************************************************************************
Res Ent
Name Units Stats Search Search Path Motion Cost
------------- ----- -------- ------- ------ ---------- -------------- ------------
Die_to_Cut 1 By Unit Closest Oldest Path1 Empty: 150 fpm
Home: N1 Full: 150 fpm
(Return)
Grind_to_Coat 1 By Unit Closest Oldest Path3 Empty: 150 fpm

(Return)
Coat_to_IP 1 By Unit Closest Oldest Path4 Empty: 150 fpm

(Return)
Maitenance 1 By Unit Closest Oldest Repair Empty: 150 fpm

(Return)
********************************************************************************
* Processing *
********************************************************************************
Process Routing
Entity Location Operation Blk Output Destination Rule Move Logic

------------- --------------- ------------------ ---- ------------- --------------- ---------- ------------
Raw_MaterialA RM_storage WAIT 0
1 Raw_MaterialA Die_Casting FIRST 1
Raw_MaterialA Die_Casting WAIT 3 MIN
1 PlaneA Batch1 FIRST 6

PlaneA Cutting_buffer UNGROUP 1 PlaneA Cutting FIRST 1
PlaneA Cutting_buffer 1 PlaneA Cutting FIRST 1
PlaneA Cutting WAIT T(.25, .28, .35) MIN
PlaneA Grinding_buffer UNGROUP 1 PlaneA Grinder FIRST 1
PlaneA Grinding_buffer 1 PlaneA Grinder FIRST 1
PlaneA Grinder WAIT T(.196, .23, .27) MIN
PlaneA IandPconv UNGROUP 1 PlaneA IandP FIRST 1

PlaneA IandPconv 1 PlaneA IandP FIRST 1
PlaneA IandP WAIT T(.27,.30,.40) MIN
1 PlaneA EXIT 0.989000 1
PlaneA Scrap 0.011000
Raw_MaterialB Die_Casting WAIT 3 MIN
1 PlaneB Batch1 FIRST 6

Raw_MaterialC Die_Casting WAIT 3 MIN 1 PlaneC Batch1 FIRST 6
PlaneB Cutting_buffer UNGROUP 1 PlaneB Cutting FIRST 1
PlaneB Cutting_buffer 1 PlaneB Cutting FIRST 1
PlaneC Cutting_buffer UNGROUP 1 PlaneC Cutting FIRST 1
PlaneC Cutting_buffer 1 PlaneC Cutting FIRST 1
PlaneB Cutting WAIT T(.25, .28, .35) MIN
PlaneC Cutting WAIT T(.25, .28, .35) MIN
1 PlaneC Batch4 FIRST 1
PlaneB Grinding_buffer UNGROUP 1 PlaneB Grinder FIRST 1
PlaneB Grinding_buffer 1 PlaneB Grinder FIRST 1
PlaneC Grinding_buffer UNGROUP 1 PlaneC Grinder FIRST 1
PlaneC Grinding_buffer 1 PlaneC Grinder FIRST 1
PlaneB Grinder WAIT T(.196, .23, .27) MIN
PlaneC Grinder WAIT T(.196, .23, .27) MIN
1 PlaneC Batch2 FIRST 1
PlaneB Coating_buffer 1 PlaneB Coater FIRST 1
PlaneC Coating_buffer 1 PlaneC Coater FIRST 1
PlaneB Coater WAIT 12 MIN 1 PlaneB IandPconv FIRST 1 MOVE WITH Coat_to_IP
FOR .2 MIN THEN FREE
PlaneB IandPconv UNGROUP 1 PlaneB IandP FIRST 1

PlaneB IandPconv 1 PlaneB IandP FIRST 1
PlaneC IandPconv UNGROUP 1 PlaneC IandP FIRST 1
PlaneC IandPconv 1 PlaneC IandP FIRST 1
PlaneB IandP WAIT T(.27,.30,.40)
1 PlaneB EXIT 0.989000 1
PlaneB Scrap 0.011000
PlaneC IandP WAIT T(.27,.30,.40)
1 PlaneC EXIT 0.989000 1
PlaneC Scrap 0.011000
PlaneC Coater WAIT 12 MIN 1 PlaneC IandPconv FIRST 1 MOVE WITH Coat_to_IP
PlaneA Batch1 GROUP 24 1 PlaneA Cutting_buffer FIRST 1 MOVE WITH Die_to_Cut

PlaneA Batch4 GROUP 24 1 PlaneA Grinding_buffer FIRST 1
PlaneA Batch2 GROUP 24 1 PlaneA IandPconv FIRST 1 MOVE WITH Grind_to_Coat
PlaneB Batch1 Group 24 1 PlaneB Cutting_buffer FIRST 1 MOVE WITH Die_to_Cut
PlaneC Batch1 GROUP 24 1 PlaneC Cutting_buffer FIRST 1 MOVE WITH Die_to_Cut
PlaneB Batch4 GROUP 24 1 PlaneB Grinding_buffer FIRST 1
PlaneC Batch4 GROUP 24 1 PlaneC Grinding_buffer FIRST 1
PlaneB Batch2 GROUP 24 1 PlaneB Coating_buffer FIRST 1 MOVE WITH Grind_to_Coat
PlaneC Batch2 GROUP 24 1 PlaneC Coating_buffer FIRST 1 MOVE WITH Grind_to_Coat
Raw_MaterialB RM_storage 1 Raw_MaterialB Die_Casting FIRST 1
Raw_MaterialC RM_storage 1 Raw_MaterialC Die_Casting FIRST 1
PlaneA Scrap INC CounterA
If CounterA = 6 THEN
{
Order 1 Raw_MaterialA TO RM_storage
CounterA = 0
}
1 Junk EXIT FIRST 1
PlaneB Scrap INC CounterB
If CounterB = 6 THEN
{
Order 1 Raw_MaterialB TO RM_storage
CounterB = 0
} 1 Junk EXIT FIRST 1
PlaneC Scrap INC CounterC
If CounterC = 6 THEN
{
Order 1 Raw_MaterialC TO RM_storage
CounterC = 0
} 1 Junk EXIT FIRST 1
********************************************************************************
* Arrivals *
********************************************************************************
Entity Location Qty each First Time Occurrences Frequency Logic

------------- ---------- ---------- ---------- ----------- ---------- ------------
Raw_MaterialA RM_storage 6 3 37 N(6, .01)
Raw_MaterialB RM_storage 8 6 41 N(9, .01)
Raw_MaterialC RM_storage 10 39 N(9, .01)
********************************************************************************
* Attributes *
********************************************************************************
ID Type Classification
---------- ------------ --------------
type Integer Entity
********************************************************************************
* Variables (global) *
********************************************************************************
ID Type Initial value Stats

---------- ------------ ------------- -----------
CounterA Integer 0 None
CounterB Integer 0 None
CounterC Integer 0 None
********************************************************************************
* User Distributions *
********************************************************************************
ID Type Cumulative Percentage Value

--------------- ------------ ------------ ------------ ------------
Rawmaterialtype Discrete No 23.26 1
34.88 2
41.86 3
General Report: To-Be Creative Solution Model Output

--------------------------------------------------------------------------------
General Report
Output from C:\DOCUME~1\labauth\LOCALS~1\TEMPOR~1\Content.IE5\S76I0E74\PLANET~1.MOD
Date: Dec/12/2006 Time: 08:41:25 AM
--------------------------------------------------------------------------------
--------------------------------------------------------------------------------
LOCATIONS
Average
--------------- --------- -------- ------- --------- -------- -------- -------- ------
Die Casting.1 8 1 116 3.00 0.72 1 0 72.50
Die Casting.2 8 1 120 3.00 0.75 1 0 75.00
Die Casting.3 8 1 124 3.00 0.77 1 0 77.50
Die Casting.4 8 1 111 3.00 0.69 1 0 69.38
Die Casting.5 8 1 119 3.00 0.74 1 0 74.38
Die Casting.6 8 1 123 3.00 0.76 1 0 76.88
Die Casting.7 8 1 114 3.00 0.71 1 0 71.25
Die Casting.8 8 1 124 3.00 0.77 1 0 77.50
Die Casting 64 8 951 3.00 0.74 8 0 74.30
Cutting.1 8 1 1422 0.29 0.86 1 0 86.88
Cutting.2 8 1 1424 0.29 0.86 1 0 86.93
Cutting.3 8 1 1419 0.29 0.86 1 0 86.87
Cutting.4 8 1 1423 0.29 0.86 1 0 86.89
Cutting 32 4 5688 0.29 0.86 4 0 86.89
Grinder.1 8 1 1422 0.23 0.68 1 0 68.68
Grinder.2 8 1 1422 0.23 0.68 1 0 68.97
Grinder.3 8 1 1422 0.23 0.68 1 0 68.83
Grinder.4 8 1 1422 0.23 0.68 1 0 68.68
Grinder 32 4 5688 0.23 0.68 4 0 68.79
Coater.1 8 1 38 11.98 0.94 1 1 94.84
Coater.2 8 1 37 12.00 0.92 1 0 92.50
Coater.3 8 1 37 12.00 0.92 1 0 92.50
Coater.4 8 1 36 12.00 0.9 1 0 90.00
Coater.5 8 1 33 11.92 0.81 1 1 81.98
Coater 40 5 181 11.98 0.90 5 2 90.36
IandP.1 8 2 2808 0.32 1.89 2 2 94.56
IandP.2 8 2 2820 0.32 1.89 2 2 94.66
IandP 16 4 5628 0.32 1.89 4 4 94.61
RM storage 8 500 951 31.09 61.59 142 0 12.32
Cutting buffer 8 999999 237 14.34 7.08 18 0 0.0
Grinding buffer 8 999999 237 1.19 0.59 1 0 0.0
Coating buffer 8 999999 181 8.65 3.26 18 0 0.0
IandPconv 8 999999 235 16.24 7.95 17 1 0.0
Batch1 8 72 5706 1.78 21.18 60 18 29.43
Batch2 8 72 5688 0.61 7.33 24 0 10.19
Batch4 8 72 5688 0.84 10.00 25 0 13.90
Scrap 8 999999 70 0.0 0 1 0 0.0
LOCATION STATES BY PERCENTAGE (Multiple Capacity)
% |
--------------- --------- ------ --------- ----- | ----
IandP.1 8 5.38 0.12 94.50 | 0.0
IandP.2 8 5.28 0.11 94.61 | 0.0
IandP 16 5.33 0.12 94.55 | 0.0
RM storage 8 20.90 79.10 0.0 | 0.0
Cutting buffer 8 13.24 86.76 0.0 | 0.0
Grinding buffer 8 40.93 59.07 0.0 | 0.0
Coating buffer 8 59.38 40.62 0.0 | 0.0
IandPconv 8 5.58 94.42 0.0 | 0.0
Batch1 8 3.64 96.36 0.0 | 0.0
Batch2 8 40.01 59.99 0.0 | 0.0
Batch4 8 17.28 82.72 0.0 | 0.0
Scrap 8 100.00 0.0 0.0 | 0.0
------------- --------- --------- ----- ----- ------- ------- -----
Die Casting.1 8 72.50 0.0 17.21 0.0 0.0 10.29
Die Casting.2 8 75.00 0.0 18.93 0.0 0.0 6.07
Die Casting.3 8 77.50 0.0 18.80 0.0 0.0 3.70
Die Casting.4 8 69.38 0.0 18.74 0.0 0.0 11.88
Die Casting.5 8 74.38 0.0 16.86 0.0 0.0 8.76
Die Casting.6 8 76.88 0.0 18.73 0.0 0.0 4.39
Die Casting.7 8 71.25 0.0 19.47 0.0 0.0 9.28
Die Casting.8 8 77.50 0.0 19.02 0.0 0.0 3.48
Die Casting 64 74.30 0.0 18.47 0.0 0.0 7.23
Cutting.1 8 86.88 0.0 13.12 0.0 0.0 0.0
Cutting.2 8 86.93 0.0 13.07 0.0 0.0 0.0
Cutting.3 8 86.87 0.0 13.13 0.0 0.0 0.0
Cutting.4 8 86.89 0.0 13.11 0.0 0.0 0.0
Cutting 32 86.89 0.0 13.11 0.0 0.0 0.0
Grinder.1 8 68.68 0.0 31.32 0.0 0.0 0.0
Grinder.2 8 68.97 0.0 31.03 0.0 0.0 0.0
Grinder.3 8 68.83 0.0 31.17 0.0 0.0 0.0
Grinder.4 8 68.68 0.0 31.32 0.0 0.0 0.0
Grinder 32 68.79 0.0 31.21 0.0 0.0 0.0
Coater.1 8 94.84 0.0 5.16 0.0 0.0 0.0
Coater.2 8 92.50 0.0 7.50 0.0 0.0 0.0
Coater.3 8 92.50 0.0 7.50 0.0 0.0 0.0
Coater.4 8 90.00 0.0 10.00 0.0 0.0 0.0
Coater.5 8 81.98 0.0 18.02 0.0 0.0 0.0
Coater 40 90.36 0.0 9.64 0.0 0.0 0.0
RESOURCES
------------- ----- --------- -------- ------- ------- ------- --------- ------
Die to Cut 1 8 237 0.08 0.0 0.08 0.0 4.64
Grind to Coat 1 8 237 0.25 0.0 0.25 0.0 12.47
Coat to IP 1 8 179 0.11 0.0 0.11 0.0 4.33
Maitenance 1 8 26 7.75 0.06 0.13 0.0 42.36

% %
------------- --------- ------ ------ ------- ----- ----
Die to Cut 8 4.35 0.29 4.05 91.31 0.0
Grind to Coat 8 12.47 0.0 12.47 75.05 0.0
Coat to IP 8 4.33 0.0 4.33 91.35 0.0
Maitenance 8 42.00 0.36 0.36 57.28 0.0
FAILED ARRIVALS

Name Name Failed
------------- ---------- ------
ENTITY ACTIVITY

------------- ----- --------- ------- ------- --------- --------- -------
PlaneA 1324 6 59.20 0.65 18.95 3.92 35.66
PlaneB 1902 66 89.51 0.37 17.28 15.92 55.92
PlaneC 2328 12 91.62 0.37 17.98 15.92 57.34
Junk 70 0 83.85 0.46 18.96 12.49 51.93
% %
------------- ------- --------- ------------ -------
PlaneA 1.10 32.02 6.63 60.25
PlaneB 0.42 19.31 17.79 62.48
PlaneC 0.41 19.62 17.38 62.58
Junk 0.55 22.61 14.90 61.94

Toy Airplane Manufacturing Mini Project: Christian Mickelson Ted Pelzer Todd Madole IE 4235

Uploaded by

Copyright:

Available Formats

You might also like

Toy Airplane Manufacturing Mini Project: Christian Mickelson Ted Pelzer Todd Madole IE 4235

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Toy Airplane Manufacturing Mini Project: Christian Mickelson Ted Pelzer Todd Madole IE 4235

Uploaded by

Copyright:

Available Formats

Toy Airplane Manufacturing

Model Building and Assumptions:

(Assuming worst case scenario for operation times)

1505 minutes/480 minutes in a day = 3.1 machines => 4 Cutting machines

717 raw material entities * 3 minute operation time = 2151 minutes

To-Be Model; Using specifications of Case Study

Resource Quantity Change Average Utilization

Resource Quantity Change Average Utilization

LOCATION STATES BY PERCENTAGE (Multiple Capacity)

LOCATION STATES BY PERCENTAGE (Single Capacity/Tanks)

RESOURCE STATES BY PERCENTAGE

Entity Location Total

ENTITY STATES BY PERCENTAGE

General Report: To-Be Model Output

RESOURCE STATES BY PERCENTAGE

Average Average Average Average Average

Formatted Listing of To-Be Model

Time Units: Minutes

Name Cap Units Stats Rules Cost

Loc Frequency First Time Priority Logic

Die_Casting.1 E(120) Min 99 GET 1 Maitenance

Die_Casting.2 E(120) Min 99 GET 1 Maitenance

Die_Casting.3 E(120) Min 99 GET 1 Maitenance

Die_Casting.4 E(120) Min 99 GET 1 Maitenance

Die_Casting.5 E(120) Min 99 GET 1 Maitenance

Die_Casting.6 E(120) Min 99 GET 1 Maitenance

Die_Casting.7 E(120) Min 99 GET 1 Maitenance

Die_Casting.8 E(120) Min 99 GET 1 Maitenance

Name Speed (fpm) Stats Cost

Name Type T/S From To BI Dist/Time Speed Factor

Net Node Location

Grind_to_Coat 1 By Unit Closest Oldest Path3 Empty: 150 fpm

Coat_to_IP 1 By Unit Closest Oldest Path4 Empty: 150 fpm

Maitenance 1 By Unit Closest Oldest Repair Empty: 150 fpm

Entity Location Operation Blk Output Destination Rule Move Logic

1 PlaneA Batch1 FIRST 6

1 PlaneA Batch2 FIRST 1

PlaneA IandPconv UNGROUP 1 PlaneA IandP FIRST 1

1 PlaneB Batch1 FIRST 6

PlaneB IandPconv UNGROUP 1 PlaneB IandP FIRST 1

PlaneA Batch1 GROUP 24 1 PlaneA Cutting_buffer FIRST 1 MOVE WITH Die_to_Cut

Entity Location Qty each First Time Occurrences Frequency Logic

ID Type Initial value Stats

ID Type Cumulative Percentage Value

General Report: To-Be Creative Solution Model Output

RESOURCE STATES BY PERCENTAGE

Entity Location Total

Average Average Average Average Average

You might also like