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Analysis of the Material Handling Requirements for Flexible Manufacturing System Case Study: Line 155

Project Overview. Problem DefinitionLEGO has not been able to create a method for calculating the number of material handlers that are required to support their production schedule.Project ObjectiveTo deliver a model for determining the number of material handlers needed for the production of any

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Analysis of the Material Handling Requirements for Flexible Manufacturing System Case Study: Line 155

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    1. Analysis of the Material Handling Requirements for Flexible Manufacturing System Case Study: Line 155 Jessica Daly and Steven Tompkins LEGO Systems, Inc. Faculty Advisor: Dr. William Brown Corporate Advisor: Aimee Crisanti, Senior Production Engineer

    2. Project Overview Problem Definition LEGO has not been able to create a method for calculating the number of material handlers that are required to support their production schedule. Project Objective To deliver a model for determining the number of material handlers needed for the production of any given product on Assembly Line 155.

    3. Solution Methodology Determine Material Handler Functions Define the characteristics of the Line that need to be quantified Determine variables for model Design logic equations that accurately represent the system Calculate the baseline of the system Design a final model

    4. Material Handler Functions Dedicated Material Handling Functions involve the loading of the following: Box Erector Literature Special Counters Parts Feeders Bag Feeders Conveyors Decal Dispensers Other Functions Product packaging removal and clean-up Machine maintenance

    5. System Characteristics Capacity of Equipment Line Speed Types of Equipment Used Operation Times

    6. Equation Variables Line Rate Type of Equipment Time for Loading Equipment P-Box Quantity Based on Weight of Part Quantity of Parts Per Piece of Equipment Number of Actual Material Handlers Used

    7. Sample Equation Dedicated Material Handling Time Equation (Rate of Line/Reload Amount)*(Time to Reload)*(Quantity needed in Final Assembly) (Rate/P-Box Qty)*(.33mins)(1)=DMHT (Mins/Hr)

    8. Baseline of System Average Percent Dedicated Material Handling Time = Approx. 70%

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