Process
Improvement Case Study
Door
Assembly Process
Scenario 1
Use one of the Assembly Operators to
begin a pre-setup
Looking at a layout of the process, there are two assembly and glue operators that work in parallel.
Theoretically, one assembly operator could leave and the operation would continue to run, although at a reduced rate. When the operator leaves, effects how long production will operate at the reduced rate, but will also impact how long the setup will take.
Model Logic:
The Arena model is constructed so that Assembler 2 can leave to perform setups based on the number of doors remaining in the current batch. The schedule below shows the setup times if Assembler 2 starts the setup with the associated doors remaining.
Setup Schedule:
Doors Remaining |
Set Up Time |
0 |
~ TRIA(20,30,65) |
10 |
~ TRIA(20,30,50) |
20 |
~ TRIA(20,25,45) |
30 |
~ TRIA(15,22,40) |
40 |
~ TRIA(13,21,40) |
50 |
~ TRIA(12,20,39) |
Use the simulation model and the cost data below to determine the best time for Assembler 2 to be released to perform pre-setup tasks. Use the default daily door assembly schedule. Remember to run enough days in order to improve the confidence level of your results. Be sure to include the total costs (standard and over time) associated with each option in your report.
Cost Data:
Assembly Operator |
Standard Time |
$15.00/hr |
Over Time |
$20.00/hr |
|
Clamp Operator |
Standard Time |
$20.00/hr |
Over Time |
$27.50/hr |
|
Putty Operator |
Standard Time |
$15.00/hr |
Over Time |
$20.00/hr |
Note: Overtime begins after 7.6 hours
Objective: Minimize overtime to reduce costs
You need to determine:
- Cost if Assembler 2 doesn't leave
- Cost if Assembler 2 leaves with 10 doors remaining
- Cost if Assembler 2 leaves with 20 doors remaining
- Cost if Assembler 2 leaves with 30 doors remaining
- Cost if Assembler 2 leaves with 40 doors remaining
- Cost if Assembler 2 leaves with 50 doors remaining