Jai Hind Cycles, Inc. Manufacturing Simulation Using ProModel

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

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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

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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

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Floor Plans
Scenario 1 2
Scenario 3
Scenario 4
500,000 ft2
500,000 ft2
900 ft2
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Entity Flow Diagram
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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

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Verification and Validation

• Verification
• Dummy variables
• Animation
• Trace Command
• Validation
• Statistical variation
• Animation and trace techniques
• Sensitivity analysis

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Results
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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.

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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)

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Questions???????Jai Hind Cycles, Inc.
Manufacturing Simulation Using ProModel

• Daniel Ball and Debbie Leach
• Fall 2000