1. Toy Airplane Manufacturing
Ted Pelzer
Todd Madole
Christian Mickelson

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

3. 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

4. Given Data

5. 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

6. 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

7. As-Is Model

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

9. AGV Analysis
Analyzed AGV path networks
Both needed 3 AGVs

10. To-Be
Demand increase of 30%

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

12. 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