ToyAirplaneManufacturing.docVIP

Toy Airplane Manufacturing Mini Project Christian Mickelson Ted Pelzer Todd Madole IE 4235 Case Study 1: Toy Airplane Manufacturing A toy company produces three types (A,B and C) of a toy aluminum airplanes in the following daily volumes: A=1000 B=1500 and C=1800. The company expects demand to increase for its products 30 percent over the next six months and needs to know the total machines, AGV’s and operators that will be required. All planes go through five operations except for plane A, which skips the cutting operation. Following is a list of operation times, move times and resources used: After die casting, planes are moved to each operation in batch sizes of 24. Input buffers exist at each operation. The factory operates eight hours a day, five days per week. The factory starts out empty at the beginning of each day and ships all parts produced at the end of the day. The die caster experiences downtime every 30 minutes exponentially distributed and takes 8 minutes normally distributed with a standard deviation of 2 minutes to repair. One maintenance person is always on duty to make repairs. Model Building and Assumptions: The .47 grinding time was ignored in the data set because it is a statistical outlier that does not fit the rest of the data. It can be assumed that this time was caused do to some non- regular operating error. It was also assumed that the AGVs move the appropriate speed and distances required for the given move times. Batches consist of 24 planes of the same type. Operation times are the same for each type of plane and any change over in tooling is also assumed in the operation time. Each machine requires at least one operator. Additional operators would be required depending on how the company applies benefits and break times. Each simulation model also includes a system that reorders more raw materials when 6 planes are added to scrap. As-Is Model First an as-is model was constructed for the facility. Initially, the team viewed