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 ft Mach ft Mach ft Mach ft Mach ft Mach ft 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 –Tool Changes 34 to 49 per day 41.5 average Simulation results –Exits 15 to 22 per day –Tool Changes 45 to 50 per day 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