Toy Airplane Manufacturing Ted Pelzer Todd Madole Christian Mickelson

Outline Problem statement Assumptions Deterministic Modeling As-is model To-be model Best solution

Problem Statement A toy company produces 3 types of planes Expected demand increase of 30% Travel in batches of 24 using AGVs 8 hours of production in one day Determine the total machines, AGVs and operators required A 1000 B 1500 C 1800

Given Data

Assumptions Ignored statistical outliers Move times determined speed and distances Batches consist of similar plane type Operation times are the same for each plane Any retooling is assumed in operation time Number of operators must equal number of machines

Deterministic Modeling (Assuming worst case scenario for operation times) Processing Time * Total Planes = Total minutes required Total Minutes required /Total time in day = Total Machines needed Cutter: .35 min * 4300 planes = 1505 minutes required 1505/480 = 3.1 machines => 4 Cutting machines

As-Is Model

As-Is Model Every 30 minutes a Die Casting machine needed to be serviced Repair time is N(8,2)

AGV Analysis Analyzed AGV path networks Both needed 3 AGVs

To-Be Demand increase of 30%

Best Model Reduce downtime to every 120 minutes Percent Yield Increased to 3-Sigma Reduced scrap from 805 to 63 planes

Conclusion Implement the creative solution if possible. Increasing the efficiency Reducing the overall number of machines in the facility and increasing quality will Reduce machine costs Reduce workforce costs Reduce material costs Reduce WIP