Toy Airplane Manufacturing

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

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 gt 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