Factory analysis simulation 2
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Production line process analysis using Autodesk process analysis software.
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Factory analysis simulation 2
- 1. 1840 Factory Analysis and Modeling 2017 |REPORT RA’UF TAILONY 08/18/2017
- 2. 1 Input Data Operations input data
- 3. 2 Operation # Cycle Time [sec.] MTBF [Hrs] MTTR [Min] Reject Rate 30 148.0 441.0 0.7 - 40 120.0 180.0 2.0 - 50 77.0 160.0 3.5 2.5% 60 188.0 441.0 0.7 - 70 307.0 441.0 0.7 - 80 188.0 441.0 0.7 - 100 357.3 180.0 2.0 - 110 300.0 180.0 2.0 2.5% 120 357.3 441.0 0.7 - 130 300.0 180.0 2.0 - 140 357.3 441.0 0.7 - 150 87.0 441.0 0.7 - 170 48.0 180.0 2.0 2.5% 190 35.0 180.0 0.0 - 210 229.0 441.0 0.7 - 220 65.0 180.0 2.0 - 230 55.0 441.0 0.7 - 310 100.0 441.0 0.7 - 320 86.0 441.0 0.7 - 330 31.0 180.0 2.0 - 340 40.0 180.0 2.0 - 350 253.0 180.0 2.0 - 410 57.0 180.0 2.0 - 420 182.0 180.0 2.0 - 520 350.0 441.0 0.7 - 530 64.0 180.0 2.0 - 540 202.0 441.0 0.7 - 550 35.0 180.0 2.0 - 560 76.0 180.0 2.0 - 710 241.0 180.0 2.0 - 820 60.0 441.0 0.7 - 830A 101.0 180.0 2.0 2.5% 830B 101.0 180.0 2.0 2.5% 840 75.0 180.0 2.0 - 850 328.0 441.0 0.7 860A 476.1 120.0 3.0 5.0% 860B 476.1 120.0 3.0 5.0% 880 191.0 441.0 0.7 - 890 300.0 150.0 2.0 - 910 190.0 441.0 0.7 - 920 51.0 441.0 0.7 - 930 300.0 200.0 2.0 - Model Assumptions ■ Factory is up 18.4 hrs/day.
- 4. 3 ■ Factory is up 312 days/year. ■ No translational motion for operators. ■ Stations sequences are Asynchronous. ■ Machine setup time is zero. ■ Minimum quantity produced/station = 1. ■ All stations are processing in sequence except pa (op420, op520, op530, op540, op550, op710). ■ Up Time = 93.9 %. ■ Factory Capacity Final Goal = 60,000 units annually (192 units/day). Line Efficiency and Cycle Time Analysis Results 1. Capacity Goal = 30 K units annually
- 7. 6
- 9. 8
- 10. 9 Diff Loop
- 11. 10
- 12. 11 TBU Loop
- 13. 12
- 14. 13 2. Capacity Goal = 50 K units annually Main Assy Loop
- 15. 14
- 16. 15
- 18. 17
- 19. 18 Diff Loop
- 20. 19
- 21. 20 TBU Loop
- 22. 21
- 23. 22 3. Capacity Goal = 60 K units annually Main Assy Loop
- 24. 23
- 26. 25
- 27. 26 Diff Loop
- 28. 27
- 29. 28 TBU Loop
- 30. 29
- 31. 30 Overall Factory Analysis Results 30 k production Main Assy Loop Gear Train Loop Diff. Loop TBU Loop Whole Factory Efficiency 96.4% 100% 100% 98.8% 98.8% Average production rate 92.59 96.37 96.78 94.9 95.16 Blocked Stations - - - - - Beyond Takt Time stations - - - - - 50 k production Main Assy Loop Gear Train Loop Diff. Loop TBU Loop Whole Factory Efficiency 96.1% 99.96% 100% 98.45% 98.63% Average production rate 153.7 159.94 160 157.52 157.79 Blocked Stations - - - - - Beyond Takt Time stations - - - OP860A,860B - 60 k production Main Assy Loop Gear Train Loop Diff. Loop TBU Loop Whole Factory Efficiency 95.9% 99.85% 100% 93% 97.18% Average production rate /Day 184.25 191.73 192.55 178.69 186.81 Blocked Stations - - - OP820,830A,830B, 840,850 - Beyond Takt Time stations - - - OP860A,860B -
- 32. 31 70K units annually (Future Goal) Main Assy Loop
- 33. 32
- 34. 33 TBU Loop
- 35. 34 In-house vs. Chrysler Factory model 30 K /year 50 K /year 60 K /year 70 K /year In-house 860A, 860B 860A,860B 520, 140, 860A, 860B 70,110,130,520,140,850 ,860A,860B Chrysler 860A 100, 850 70 70, 110, 130 Conclusions and Recommendations The Factory is Capable of producing 30,000 units annually with no issues, but optimizations opportunity is available by combining the low cycle time stations in the loops called “Main Assy, Gear Train, TBU”. Regarding the 50,000 annual production goal; all loops are capable of achieving that except stations called “OP860A, OP860B” are exceeding the production Takt Time Margin, to reach the production goal; the cycle time for these stations need to be reduced by at least 30%. To achieve a 60,000 annual production, the pallets blocking need be cleared from “TBU loop” by reducing cycle times of stations “OP860A, OP860B” by 40%. Op520 and OP140 are exceeding the Takt time which need to be fixed as well. For the stretched production goal of 70,000 units/year, “TBU Loop” stations op860A, 860B are causing blockage, while “Main Assy Loop” stations OP70,110, 130, 520, 140, are passing Takt Margin.