Jai Hind Cycle Inc. Presented By: Mike Seide Sean McCauley Matt Zbylut Rebecca Gramse

Outline Introduction Assumptions As-Is Model Deterministic Model FMS To-Be Model Results / Recommendation

Introduction Jai Hind Cycles produces bicycles and is planning on introducing a new model of mountain bike strictly for the export market The company currently runs one shift per day and is considering replacing their existing factory layout with a cellular, group technology layout

Assumptions Production at 82,000 units would be interpreted as 328 bikes per production day  Of those 328 bikes, 200 would be regular bikes and 128 would be mountain bikes 250 work days/year; 2080 work hours/year; 8 hour work days Anything not produced is sub-contracted or purchased from the market for the final assembly A 100 hour warm-up period was used to reach steady state

As-Is Model Job shop facility layout Current Production of 200 regular bikes per day High quantity of casting and final assembly machines Inefficient workspace

Building the As-Is Model

Deterministic Model – Bottleneck Model Bottleneck model is used to provide starting estimates of the FMS design parameters Performed the bottleneck model assuming that 333 bikes will be leaving the system

FMS Used in Model Cellular Manufacturing Layout Use of simple machines, no custom jigs Use of AGVS for transportation Cross Trained Workforce

To-Be Model Assumptions AGVS speed is set to a maximum of 5 mph Human workers will transport the goods between cells Human worker speed empty is 300 fpm and full is 250 fpm The operators and AGVS will return home when idle Production runs two 8 hour shifts per day AGVSs are used to transport raw materials from Raw Material Receiving/Storage to the designated queues. Each cell contains 1 machine of each type

To-Be Model Incorporated Group Technology with Cellular Manufacturing  Part Families, like characteristics AGVS  Delivering raw materials to cells Workers  Path network, constantly moving to different cells for assistance or assembly

Building the To-Be Model

To-Be Model Results Bottlenecks  Frame cell and Handle Bar cell was over utilized  Reduced by adding cells to both Production increased to 333 bikes per day Reduced labor by adding AGVS delivery system of raw materials Reduced # of workers by incorporating floating worker design

Recommendations Implement the Group Technology Cellular Manufacturing layout Add capacity to the frame and handle bar cells Use AGVS to reduce workers and increase efficiency Use workers to transport materials between cells

Questions??