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Jai Hind Cycle Inc. Presented By: Mike Seide Sean McCauley Matt Zbylut Rebecca Gramse. Introduction. 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 cycle inc

Jai Hind Cycle Inc.

Presented By:

Mike Seide

Sean McCauley

Matt Zbylut

Rebecca Gramse

introduction
Introduction
  • 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
assumptions
Assumptions
  • Production at 82,000 units would be interpreted as 328 bikes per 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
  • A 100 hour warm-up period was used to reach steady state
as is model
As-Is Model
  • Job shop facility layout
  • Current Production of 200 regular bikes per day
  • High quantity of casting and final assembly machines
  • Inefficient workspace
to be model assumptions
To-Be Model Assumptions
  • AGVS speed is set to a maximum of 5 mph
  • Human workers will transport the goods between stations
  • Human worker speed empty is 300 fpm and full is 250 fpm
  • The operators and AGVS will return home when idle
  • Production runs two 8 hour shifts per day
  • AGVSs are used to transport raw materials from Raw Material Receiving/Storage to the designated queues.
  • Each cell contains 1 machine of each type
to be model
To-Be Model
  • Incorporated Group Technology with Cellular Manufacturing
    • Part Families, like characteristics
  • AGVS
    • Delivering raw materials to cells
  • Workers
    • Path network, constantly moving to different cells for assistance or assembly
fms used in model
FMS Used in Model
  • Cellular Manufacturing Layout
  • Use of simple machines, no custom jigs
  • Use of AGVS for transportation
  • Cross Trained Workforce
to be model results
To-Be Model Results
  • Bottlenecks
    • Frame cell and Handle Bar cell was over utilized
    • Reduced by adding cells to both
  • Production increased to 333 bikes per day
  • Reduced labor by adding AGVS delivery system of raw materials
  • Reduced # of workers by incorporating floating worker design
recommendations
Recommendations
  • Implement the Group Technology Cellular Manufacturing layout
  • Add capacity to the frame and handle bar cells
  • Use AGVS to reduce workers and increase efficiency
  • Use workers to transport materials between cells