1. Project : Man Utilization FMS Cell Unit 1104 DSES 6620 Spring 2002 William Harris

2. 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

3. Use Simulation to: Understand existing process Predict effect of new process Guide new process insertion

4. Model Distances Mach 1 - 80 ft Mach 2 - 100 ft Mach 3 - 120 ft Mach 4 -140 ft Mach 5 - 10ft Mach 6 - 30 ft Assumptions –Operator efficiency –Operator tasks –Ignore Machine breakdowns Shifts & breaks –Material arrival uninterrupted

5. 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

6. 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

7. Results Existing process –Operator engaged 75% –Machinery < 30% –23.8 exits/day New Process –Operator engaged 92% –Machinery < 20% –26 exits/day

8. Recommendations Assign a person to service cutters Engage an unload station