M6205 SYSTEM SIMULATION AND MODELLING TERM PROJECT Productivity Improvement in Automated Manufacturing Cell for Die Casting M6205 SYSTEM SIMULATION AND MODELLING TERM PROJECT

PROBLEM Statement XYZ company manufactures Aluminium compressor cover castings in an automated manufacturing cell. Current cell has the capacity to produce 40 parts per hour with annual volume of 2,22,000 parts. Customer requirement increased to 2,30,000 parts per annum. Company decided to increase its production rate to meet the demand. Analyze efficient and cost effective solution to increase the production rate.

CASTING PROCESS FLOW Metal Arrival Pouring Solidification Cooling Decoring Cutting Inspection Shipping

CURRENT SYSTEM System Layout Similar cell Model

Simulation Specification Entity Molten metal Casting Resources Die 1 Die 2 Die 3 Die 4 Decoring machine Cutting machine Processes Solidification Cooling Decoring Cutting Attributes Entity type: Molten metal, Casting Robot 1 pick time Robot 2 pick time Entity picture Time IN Transporters Robot 1 Robot 2

Assumptions made for the model Molten metal arrives every 60 mins with quantity 41 units. Entities enters the system only if the queue in the furnace block is less than 61 units All 4 dies run with predefined capacity schedule Cooling station is considered as a holding station. Rejection rate of the parts at inspection station is taken as 10% Simulation runs for 25 days and 30 replications

i/p DATA ACQUISTION AND ANALYSIS Knockout process time: NORM (20,1.50) Number of data point: 25 Solidification process time: NORM (297,2.36) Number of data points :20 Cutting process time: NORM (16.7,0.513) Number of data points: 20

ARENA MODEL

ANIMATION – Arena model

Verification & validation Parameters Existing model Units Metal time between arrivals 60 mins Metal arrival quantity 41 nos Metal first creation 120 Furnace decision NQ (Request 1. Queue) < 62 No of die 4 Holding Furnace Solidification 1.WIP == 0 || Solidification 2.WIP == 0 || Solidification 3.WIP == 0 || Solidification 4.WIP == 0 Decide die to pour Solidification 1.WIP == 0|| Solidification 2.WIP == 0|| Solidification 3.WIP == 0|| Solidification 4.WIP == 0 Solidification time NORM (297,2.36) secs Knockout process delay NORM (20,1.5) Production time 18.5 hrs/day Results of simulation trial: Number of replication 30 Sample Mean (Production/month) 17378.533 Sample standard deviation 33.598 95% confidence interval Lower:17299 Upper:17446 The Average production output: 41.5 nos /Hr. 96.25% matches with existing scenario Current model simulates the actual scenario

Experimentation 1. Forced Die Cooling 2. Addition of 5th die 3. Employing an operator Additional die To increase the productivity Increases Robot utilization Investment=20,00,000 INR /Die An extra operator is employed. Will decrease die preparation time Increasing the total production time per day Investment=3,00,000 INR /operator To reduce solidification time by 60 secs Will have a direct impact on productivity Investment=6,00,000 INR /Die 11

Comparison of simulation results   Existing Forced Die cooling 5th Die addition Reduced die preparation Number of replication 30 Sample Mean (production/month) 17378.533 19444.100 19639.167 18801.367 Sample standard deviation 33.598 44.689 43.172 36.578 95% confidence interval Lower:17299 Upper:17446 Lower:19360 Upper:19533 Lower:19557 Upper:19716 Lower:18719 Upper:18860 Does not meet the monthly requirement *Required monthly production :19167

Return on investment calculation No. of parts (Existing) 17378 nos/month Models Forced cooling 5th die addition Units No. of parts manufactured per month (modified) 19444 19639 Additional parts produced 2066 2261 Manufacturing Cost/part ₹ 59.00 INR/part Selling Cost/part ₹ 118.00 Profit/part Additional profit ₹ 1,21,894.00 ₹ 1,33,399.00 INR/month Investment ₹ 24,00,000.00 ₹ 20,00,000.00 INR ROI ( months) 19.7 15.0 Months ROI ( years) 1.64 1.25 Years Lowest ROI “Best of the solutions”

Employing Additional operator conclusion Forced Die Cooling By introducing forced die cooling,customer requirement is met to a certain extent. ROI is greater than that of addition of 5th die solution. Addition of 5th die By adding an extra die increases the productivity. On the other hand robot utilization and efficiency is increased. When compared to other solutions ROI is minimal Employing Additional operator Employing an additional operator decreases the preparation time but the solution doesn’t meet the monthly requirement and customer objective