Jai Hind Cycles Inc

1
Jai Hind Cycles Inc

• Matt Zbylut
• Mike Rosenthal
• Christian Mickelson
• Todd Madole

2
Background

• Jai Hind Cycles produces bicycles and is planning
  on introducing a new model of mountain bike
  strictly for the export market.
  
• The company currently runs one shift per day and
  is considering replacing their existing factory
  layout with a cellular, group technology layout.
  

3
Assumptions

• Production at 82,000 units would be interpreted
  as 328 bikes a production day
  
• Of those 328 bikes, 200 would be regular bikes
  and 128 would be mountain bikes
  
• 250 work days/year 2080 work hours/year 8 hour
  work days
  
• Anything not produced is sub-contracted or
  purchased from the market for the final assembly
  
• In the proposed cellular model, decreasing
  process time is the equivalent of adding
  machines/capacity.
  
• The processing of handlebars for each bike takes
  a similar amount of time due to restrictions of
  the software.
  
• A 100 hour warm-up period was used to reach
  steady state.

4
As-Is Model

• Building the current layout began by determining
  how to divide the bill of materials into
  different locations.
  
• It was necessary to determine the processing
  times for each entity and its flow through the
  shop.
  
• It was determined that there would be four
  assembly stations. There is a frame, seat post,
  handlebar, and drive chain assembly station.
  
• Using a 100 hour warm-up period and an 8 hour
  run-time we were able to produce 259 complete
  bikes.

5
As-Is Model
6
As-Is Model
7
To-Be Model

• Due to the limitations of the student model it
  became necessary to black box each cell and
  compute the processing times for each entity at
  each process.
• Each cell is responsible for producing either a
  frame, seat assembly, drive assembly or handle
  bar assembly.
  

8
To-Be Model
9
To-Be Model
10
Recommendations

• Jai Hind Cycles Inc. should stay as a job shop as
  demand increases to 82,000 bikes/year.
  
• The cost of implementing a cellular system would
  be great
  
• Addition of multiple machines and cells
• The To-Be model was compared to a job shop model
  that produced both mountain and regular bikes.
  The job shop required no additional machines to
  meet the new demand

11
Questions