1. Jai Hind Cycles, Inc. Manufacturing Simulation Using ProModel Daniel Ball and Debbie Leach Fall 2000

2. Introduction Jai Hind Cycles, Inc. (JHC) manufactures bicycles for the domestic market Currently produces 200 bikes per day Market demand is 308 bikes per day Consists of 4 sub-assemblies: bike frame handlebar and stem assembly saddle post assembly drive chain assembly

3. Scope Model current production system (Scenario 1): 200 Bikes per day 480 minute shift per day (8 hours) Job shop floor plan layout Model increased production system (Scenario 2): 308 Bikes per day 480 minute shift per day (8 hours) Job shop floor plan layout Increased number of workers

4. Scope (cont.) Model new departmental relocation layout (Scenario 3): 308 Bikes per day 480 minute shift per day (8 hours) Increased number of workers Redesigned job shop floor layout Model new cellular layout (Scenario 4): 308 Bikes per day 480 minute shift per day (8 hours) Cellular floor plan layout Increased number of workers

5. Floor Plans Raw Material Storage CuttingMolding BendingCasting Welding Final Assembly Offices Warehouse & Shipping Raw Material Storage Cutting Molding Bending Casting Welding Final Assembly Offices Warehouse & Shipping Casting Cutting Molding Final Assembly I Bending Raw Material Storage Scenario 1 & 2Scenario 3Scenario 4 500,000 ft 2 900 ft 2

6. Entity Flow Diagram Raw Material Storage Cutting Molding Casting Handlebars Handlebar Plugs Handlebar Stem Bending Final Assembly I Handlebar and Stem Assembly Final Assembly II Bicycle

7. Assumptions Handlebar and stem assembly is the limiting factor Entities follow JIT system (Just-in-Time) No shortage of entities No process or machine downtimes Final Assembly I and II capacity is number of workers Changes in handlebar and stem assembly mimic changes in other assemblies Handlebar and stem assembly do not cause delays in other assemblies Each of the other subassembly parts are readily available at the Final Assembly II location

8. Verification and Validation Verification “Dummy” variables Animation Trace Command Validation Statistical variation Animation and trace techniques Sensitivity analysis

9. Results

10. Conclusions The increased bike production can be achieved by increasing the number of workers 53% at Final Assembly I and 55% at Final Assembly II. Bike production is limited by the number of workers at the Final Assembly stations. Changes in the layout of the plant do not increase bike production.

11. Recommendations Compare modeled system results to actual system Perform a cost-benefit analysis of number of workers needed Implement Scenario 2 (increased amount of workers)

12. Questions??????? Jai Hind Cycles, Inc. Manufacturing Simulation Using ProModel Daniel Ball and Debbie Leach Fall 2000