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Toy Airplane Manufacturing

Toy Airplane Manufacturing. Ted Pelzer Todd Madole Christian Mickelson. Outline. Problem statement Assumptions Deterministic Modeling As-is model To-be model Best solution. Problem Statement. A toy company produces 3 types of planes Expected demand increase of 30%

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Toy Airplane Manufacturing

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  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 => 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

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