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Jai Hind Cycles Inc

Jai Hind Cycles Inc. Matt Zbylut Mike Rosenthal Christian Mickelson Todd Madole. Background. Jai Hind Cycles produces bicycles and is planning on introducing a new model of mountain bike strictly for the export market.

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Jai Hind Cycles Inc

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  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

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