A process analysis and factory simulation results for an engine development factory, created using Autodesk process analysis software.

1. 1820 SAIC Factory Analysis and
Modeling
2017
|REPORT
RA’UF TAILONY
08/14/2017

2. 1
Input Data

3. 2
1821 Main Line Loop A
Job Item OP
Station
Type
Station Description
Cycle Time -
200K
Cycle Time -
Expanded
Category
MTTR
(Min)
MTBF
(Min)
Reject
Rate
1821 149 10 M Press Install Gear Shift Components & Oil Seal (Offline Station) 46.00 46.00 4 10 50000 0.10%
1821 003 20 S Press Diff Cup, I-Shaft Cup, Diff Seal 27.00 27.00 2 15 25000 0.20%
1821 004 30 M Load Case to Pallet and Install Lubrication Nozzle 30.00 30.00 4 10 50000 0.10%
1821 014 40 M Install Remaining Gear Shift Components 57.00 57.00 4 10 50000 0.10%
1821 016 50 M Install Pulley Cover Dowel Pins and Primary Pulley Bearing 80.00 40.00 4 10 50000 0.10%
1821 XXX 55 M Install Pulley Cover Dowel Pins and Primary Pulley Bearing (2) 40.00 4 10 50000 0.10%
1821 017 60 A RTV Middle Case Pulley Cover Surface 33.00 33.00 1 15 15000 0.20%
1821 019 70 M Install Cover and Pulley assembly to Case 61.00 61.00 4 10 50000 0.10%
1821 022 80 M Hand Start and Zero Torque Pulley Cover Bolts 80.00 40.00 4 10 50000 0.10%
1821 XXX 85 M Hand Start and Zero Torque Pulley Cover Bolts (2) 40.00 4 10 50000 0.10%
1821 021 90 A Auto torque twenty one Pulley Cover Bolts 29.00 29.00 3 10 35000 0.20%
For Torque
Stations 3 Retry
Attempts Prior
to Rejecting
1821 023 100 M Back-up - Manually Torque Case Bolts (Was install/torque speed sensors) 52.00 52.00 4 10 50000 0.10%
1821 024 110 A Rollover Station 45.00 45.00 1 15 15000 0.10%
1821 005 120 S
Semi-Auto Vacuum and Lube Case, And Press Reverse Clutch Piston, Dam, Spring, and
Snap Ring.Assemble Clutch Stack Offline & Verify, Install Clutch Stack
80.00 80.00 2 15 25000 0.20%
1821 009 130 A Gage Reverse Clutch Stack 43.00 43.00 1 30 15000 0.10%
1821 150 140 M Select Snap Ring and verify.Install Snap Ring & Verify Snap Ring Seated 69.50 69.50 4 10 50000 0.10%
1821 007 150 A Piston Travel Check and Leak Test 53.50 53.50 1 30 15000 0.20%
1821 008 156 R Repair Station (For Repairs ONLY) NA NA 4 10 50000 50.00%
1821 010 160 M Install Oil Guide Boss 55.00 38.00 4 10 50000 0.10%
1821 152 170 M Install BRG, Planet Carrier, BRG, & FWD Clutch 53.00 38.00 4 10 50000 0.10%
1821 XXX 175 M Install BRG, Planet Carrier, BRG, & FWD Clutch (2) 32.00 4 10 50000 0.10%
1821 025 180 A Gage Input Shaft 37.00 37.00 1 30 15000 0.10%
1821 153 190 S Gage Oil Plate (Offline), Select Verify and Install Shim, & Install Oil Plate 53.00 53.00 1 30 15000 0.10%
1821 026 200 M Hand start and final Torque (12) Oil Plate Bolts 80.00 55.00 4 10 50000 0.10%
1821 XXX 205 M Hand start and final Torque (12) Oil Plate Bolts (2) 53.50 4 10 50000 0.10%
1821 028 210 M Install Oil Pump and Install Oil Baffle Board 83.50 55.00 4 10 50000 0.10%
1821 032 220 M Install I-Shaft and Diff, TC Hsg Dowel Pins, TC Hsg Lineup Pins 32.00 32.00 4 10 50000 0.10%
1821 031 230 M Install Chain Sprocket Thrust Washer, Snap Ring, and Check Chain Tension 37.50 37.50 4 10 50000 0.10%
1821 033 240 A Gage Bearing Surface of Intermediate and Differential Shaft 48.00 48.00 1 30 15000 0.10%
1821 034 250 A Auto RTV Middle Case Torque Convertor Joint Face 33.00 33.00 1 15 15000 0.20%
1821 100 10 S
(OFFLINE STATION) SEMI-AUTO PRESS DIFF AND T/C SEALS TO TORQUE CONVERTER
HOUSING
22.00 22.00 2 15 25000 0.20%
1821 101 20 S (OFFLINE STATION) Gage Torque Convertor (Offline Station) 35.00 35.00 1 30 15000 0.10%
1821 102 30 S
(OFFLINE STATION) Semi-Auto Shim Selection Install and Press Diff and I-Shaft
Bearings. Install and Fasten Dam Board
77.00 77.00 2 15 25000 0.20%
1821 154 260 M Load Torque Convertor Housing to Case 22.00 22.00 4 10 50000 0.10%
1821 035 270 M Zero Torque Twenty-Two Torque Convertor Housing Bolts 97.00 48.50 4 10 50000 0.10%
1821 XXX 275 M Zero Torque Twenty-Two Torque Convertor Housing Bolts (2) 48.50 4 10 50000 0.10%
1821 036 280 A Final Torque Twenty-Two Torque Convertor Housing Bolts 35.00 35.00 3 10 35000 0.20%
For Torque
Stations 3 Retry
Attempts Prior
to Rejecting
1821 053 290 M Load TC Install TC Holding Bar 54.00 34.00 4 10 50000 0.10%
1821 XXX 295 M Load TC Install TC Holding Bar (2) 20.00 4 10 50000 0.10%
1821 039 296 R Repair Station (For Repairs ONLY) NA NA 4 10 50000 50.00%
1822 042 300 M Unload CVT To Loop B (Included in Loop B OP 10 Cycle Time) NA NA 4 10 50000 0.10%
104.80% 4.80%

4. 3
1822 Main Line Loop B
1823 Test Loop
Job Item OP
Station
Type
Station Description
Cycle Time -
200K
Cycle Time -
Expanded
Category
MTTR
(Min)
MTBF
(Min)
Reject
Rate
1822 042 10 M Manually Load Transmission to Loop "B" 61.00 61.00 4 10 50000 0.10%
1822 044 20 M Load Valve Body Install Wiring Harness 80.00 55.00 4 10 50000 0.10%
1822 XXX 25 M Load Valve Body Install Wiring Harness (2) 50.00 4 10 50000 0.10%
1822 045 30 M Install Valve Body 80.00 55.00 4 10 50000 0.10%
1822 046 40 A Auto Torque (14) Valve Body Bolts 55.00 55.00 3 10 35000 0.20%
For Torque
Stations 3 Retry
Attempts Prior to
Rejecting
1822 048 50 M Manually Install Valve Oil Filter, Manual ShiftLever and Spring Pin 43.00 43.00 4 10 50000 0.10%
1822 049 60 A RTV Oil Pan surface 37.50 37.50 1 15 15000 0.20%
1822 050 70 M Manually Install Oil Pan and Zero Torque (19) Oil Pan Bolts 111.00 55.50 4 10 50000 0.10%
1822 XXX 75 M Manually Install Oil Pan and Zero Torque (19) Oil Pan Bolts (2) 55.50 4 10 50000 0.10%
1822 051 80 A Auto Torque Oil Pan 29.00 29.00 3 10 35000 0.20%
For Torque
Stations 3 Retry
Attempts Prior to
Rejecting
1822 XXX 90 M Manually Install (3) Speed Sensors and Final Torque 95.00 60.00 4 10 50000 0.10%
1822 043 100 M Install Oil Filter, Oil Cooler and Oil Level 89.50 60.00 4 10 50000 0.10%
1822 XXX 105 M Install Oil Filter, Oil Cooler and Oil Level (2) 64.50 4 10 50000 0.10%
1822 054 106 R Repair Station (For Repairs ONLY) NA NA 4 10 50000 50.00%
1822 157 110 M Manually Load Transmission to Test Loop (Included in Test Loop OP 10 Cycle Time) NA NA 4 10 50000 0.10%
52% 2%
Job Item OP
Station
Type
Station Description
Cycle Time -
200K
Cycle Time -
Expanded
Category
MTTR
(Min)
MTBF
(Min)
Reject
Rate
1823 57 10 M Load CVT to Test Loop 63.00 63.00 4 10 50000 0.10%
1823 060 20 M Leak Test + Plug 6 Ports 80.00 80.00 3 10 35000 0.20%
1823 XXX 25 M Leak Test + Plug 6 Ports (2) Parallel Process 80.00 3 10 35000 0.10%
1823 061 30 M Oil Fill CVT Transmission 17.00 17.00 4 10 50000 0.10%
1823 062 40 M Rig Station to Install Hoses and Harness 74.00 37.00 4 10 50000 0.10%
1823 XXX 45 M Rig Station to Install Hoses and Harness (2) 37.00 4 10 50000 0.10%
1829 XXX 50 A EOL Test Stand # 1 201.00 201.00 1 30 15000 0.20%
1829 XXX 60 A EOL Test Stand # 2 201.00 201.00 1 30 15000 0.20%
1829 XXX 70 A EOL Test Stand # 3 201.00 201.00 1 30 15000 0.20%
1829 XXX 75 A EOL Test Stand # 4 201.00 201.00 1 30 15000 0.20%
1823 063 66 R Repair Station (For Repairs ONLY) NA NA 4 10 50000 50.00%
1823 064 80 M Manual Derigging and Oil Drain 90.00 45.00 4 10 50000 0.20%
1823 XXX 85 M Manual Derigging (2) 45.00 4 10 50000 0.10%
1823 065 90 M Fasten TC Bracket, Install Axle Seals and Noise Insulator 69.00 34.50 4 10 50000 0.10%
1823 XXX 95 M Fasten TC Bracket, Install Axle Seals and Noise Insulator (2) 34.50 4 10 50000 0.10%
1823 067 96 R Repair Station (For Repairs ONLY) NA NA 4 10 50000 50.00%
1823 066 100 M Unload 76.00 76.00 4 10 50000 0.10%
102.10% 2.10%

5. 4
1824 Pulley Loop 1 Subassembly
1824 Pulley Loop 2 Subassembly
1825 Forward Clutch Subassembly
Job Item OP
Station
Type
Station Description
Cycle Time -
200K
Cycle Time -
Expanded
Category
MTTR
(Min)
MTBF
(Min)
Reject
Rate
1824 070 10 S Off Line Press, Bushing and Bearing on Primary Shaft in Press, Press Bushing into Primary 59.00 59.00 2 15 25000 0.20%
1824 042 20 M Install Bottom Circlip in Primary and Secondary Sheave, Install Sheave on Pulleys 72.50 37.00 4 10 50000 0.10%
1824 XXX 25 M Install Bottom Circlip in Primary and Secondary Sheave, Install Sheave on Pulleys (2) 36.00 4 10 50000 0.10%
1824 XXX 30 A Marposs Gage Roller Groove - Customer Supplied 45.00 45.00 1 30 15000 0.10%
1824 XXX 40 S Marposs Press Roller Bearing - Customer Supplied 58.00 58.00 1 30 15000 0.10%
1824 XXX 50 A Marposs Gage Tangential Play and Slide Force - Customer Supplied 60.00 60.00 1 30 15000 0.10%
1824 075 56 R Repair Station (For Repairs ONLY) NA NA 4 10 50000 50.00%
1824 076 60 M Install Top Circlip in Primary and Secondary Sheave, Vision Verification 59.00 29.50 4 10 50000 0.10%
1824 XXX 65 M Install Top Circlip in Primary and Secondary Sheave, Vision Verification 29.50 4 10 50000 0.10%
1824 077 70 S Press Seal to Primary Piston 34.00 34.00 2 15 25000 0.20%
1824 080 80 S Install Spring, Press Secondary Pulley Piston 34.00 34.00 2 15 25000 0.20%
1824 079 90 M Install Secondary Pulley Piston Cover and Snap Ring 31.00 31.00 4 10 50000 0.10%
1824 080 100 S Install Retainer and Press Bearing on Primary Shaft, Press Bearing and Gear on Secondary 54.00 54.00 2 15 25000 0.20%
1824 081 110 S Install and Torque Nuts (Offline Station) 45.00 45.00 3 10 35000 0.20%
For Torque Stations 3 Retry
Attempts Prior to Rejecting
1824 161 116 R Repair Station (For Repairs ONLY) NA NA 4 10 50000 50.00%
101.80% 1.80%
Job Item OP
Station
Type
Station Description
Cycle Time -
200K
Cycle Time -
Expanded
Category
MTTR
(Min)
MTBF
(Min)
Reject
Rate
1824 089 130 M Load Shaft to Loop 2 37.00 37.00 4 10 50000 0.10%
1824 084 140 A Measure Shaft Gap 36.00 36.00 1 30 15000 0.10%
1824 XXX 145 S Install Wheel Belt (2) (Parallel Process) 69.00 1 30 15000 0.20%
1824 085 150 S Install Wheel Belt 69.00 69.00 1 30 15000 0.20%
1824 160 145 M (OFFLINE STATION) Press Oil Nozzle & Install Park Mechanism, Gage Case Offline 35.00 35.00 4 10 50000 0.10%
1824 159 150 M Install Shim and Rear Cover, Hand Start and Zero Torque Bolts 41.00 41.00 4 10 50000 0.10%
1824 087 170 A Auto Torque 6 Cover Bolts 18.00 18.00 3 10 35000 0.20%
For Torque Stations 3 Retry
Attempts Prior to Rejecting
1824 162 180 M Unload to Mainline 27.00 27.00 4 10 50000 0.10%
1824 088 186 R Repair Station (For Repairs ONLY) NA NA 4 10 50000 50.00%
51.10% 1.10%
Job Item OP
Station
Type
Station Description Cycle Time Category
MTTR
(Min)
MTBF
(Min)
Reject
Rate
1825 093 10 S Install Forward Clutch Piston 53.00 2 15 25000 0.20%
1825 097 20 M Install Sun Gear, Clutch Stack and Gear Ring 39.00 4 10 50000 0.10%
1825 096 30 A Auto Gage Clutch Stack 45.00 1 30 15000 0.20%
1825 098 40 M Select and Install Snap Rings 53.00 4 10 50000 0.10%
1825 095 50 A Auto Leak Test and Travel Check 30.50 1 30 15000 0.20%
1825 092 60 M Install Input Shaft Seals, Install Shaft Clutch 51.00 4 10 50000 0.10%
1825 099 66 R Repair Station (For Repairs ONLY) NA 4 10 50000 50.00%
51% 1%

6. 5
1826 Differential Subassembly
1828 Valve Body Subassembly
Job Item OP
Station
Type
Station Description
Cycle Time -
200K
Cycle Time -
Expanded
Category
MTTR
(Min)
MTBF
(Min)
Reject
Rate
1826 106 10 M Manual Install Gear, Shaft Axle Gear 47.00 47.00 4 10 50000 0.10%
1826 107 20 A Gage Gear Clearance 39.00 39.00 1 30 15000 0.10%
1826 108 30 M Manual Install Shims 67.00 33.50 4 10 50000 0.10%
1826 XXX 35 M Manual Install Shims (2) 33.50 4 10 50000 0.10%
1826 109 40 A Final Measure Gear Clearance 39.00 39.00 1 30 15000 0.20%
1826 110 50 S Instal Gear Ring and Zero Torque (10) Bolts, Hand Start (2) Other Bolts 77.50 38.50 2 15 25000 0.20%
1826 XXX 55 M Zero Torque (10) Bolts, Hand Start (2) Other Bolts (2) 38.50 4 10 50000 0.10%
1826 111 60 A Fasten the Gear Ring 46.50 46.50 3 10 35000 0.20%
For Torque
Stations 3 Retry
Attempts Prior to
Rejecting
1826 112 70 S Press Bearing and Unload Differential and Intermediate Shaft 61.00 61.00 2 15 25000 0.20%
1826 113 76 R Repair Station (For Repairs ONLY) NA NA 4 10 50000 50.00%
51% 1%
Job Item OP
Station
Type
Station Description
Cycle Time -
200K
Cycle Time -
Expanded
Category
MTTR
(Min)
MTBF
(Min)
Reject
Rate
1828 117 10 M (OFFLINE BUILD) Load Solenoid Body to Pallet, Install (2) Solenoid Body Valves, Install Shift Spool 42.00 42.00 4 10 50000 0.10%
1828 118 20 M (OFFLINE BUILD) Install 5 SB Solenoids 64.00 32.00 4 10 50000 0.10%
1828 XXX 25 M (OFFLINE BUILD) Install 5 SB Solenoids 32.00 4 10 50000 0.10%
1828 119 30 M (OFFLINE BUILD) Load Valve Body to Pallet, Install (4) "Valve Body" Valves 80.00 40.00 4 10 50000 0.10%
1828 XXX 35 M (OFFLINE BUILD) Load Valve Body to Pallet, Install (4) "Valve Body" Valves 40.00 4 10 50000 0.10%
1828 122 40 M (OFFLINE BUILD) Load Solenoid to Pallet, Install (4) Valve Retainers, Install (2) Sensors 28.00 28.00 4 10 50000 0.10%
1828 122 45 M Load Solenoid Body to Pallet, Install (4) Valve Retainers, Install (2) Sensors 28.00 28.00 4 10 50000 0.10%
1828 123 50 M Install the Springs/ Accumulator/ Ball Valve / Filter onto Solenoid Valve 55.00 55.00 4 10 50000 0.10%
1828 124 60 M Install Valve Plate with Bolts 78.50 45.00 4 10 50000 0.10%
1828 XXX 65 M Flex Station 48.50 4 10 50000 0.10%
1828 127 70 M Load SB onto the Valve Body and Pre Fasten 24 Bolts 61.00 46.00 4 10 50000 0.10%
1828 125 80 A Fasten Solenoid Body Bolts (10) 32.00 32.00 3 10 35000 0.20%
For Torque Stations 3
Retry Attempts Prior
to Rejecting
1828 128 85 A Fasten Solenoid Body Bolts (10) 33.00 33.00 3 10 35000 0.20%
For Torque Stations 3
Retry Attempts Prior
to Rejecting
1828 131 96 R Repair Station (For Repairs ONLY) NA NA 4 10 50000 50.00%
1828 172 90 M Unload Valve Body from the Loop 43.00 43.00 4 10 50000 0.10%
1830 XXX 100 A Valve Body Test Stand 80.00 80.00 1 30 15000 0.20%
51.80% 1.80%

7. 6
Model Assumptions
■ Factory Capacity = 250,000 CVT annually (1000 CVT/day).
■ Factory is up 21.5 hrs/day.
■ Factory is up 250 days/year.
■ Takt Time= 1.29 minutes.
■ 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.
■ Up Time = 95%.

8. 7
Line Efficiency and Cycle Time Analysis Results
1821 Main Line Loop A

9. 8

10. 9

11. 10

12. 11
1822 Main Line Loop B

13. 12

14. 13

15. 14
1823 Test Loop

16. 15

17. 16

18. 17
1824 Pulley Loop 1 Subassembly

19. 18

20. 19

21. 20
1824 Pulley Loop 2 Subassembly

22. 21

23. 22
1825 Forward Clutch Subassembly

24. 23

25. 24
1826 Differential Subassembly

26. 25

27. 26
1828 Valve Body Subassembly

28. 27

29. 28
Overall Factory Analysis Results
1821-
loopA
1822-
loopB
1823 Test
loop
1824-
loop1
1824-
loop2
1825
forward
clutch
1826
diff.
1828
valve
body
Complete
Factory
Efficiency 97.8% 99.2% 99.1% 99.3% 99.6% 99.7% 99.6% 99.6% 99.27%
Average
production
rate
978/day 992/day 990.9/day 993/day 996/day 997/day 996/day 996/day 921/day
Most
efficient
station
OP120
(91.88%)
OP105
(74.02%)
Op20
(92.51%)
Op50
(69.23%)
OP145
(79.78%)
OP10
(61.35%)
OP70
(70.28%)
OP100
(92.25%)
-
Least
efficient
station
OP295
(22.64%)
OP 80
(33.35%)
OP30
(19.63%)
OP65
(34.01%)
OP170
(20.75%)
OP50
(35.21%)
OP35
(38.71%)
OP80
(36.97%)
-
Most time
blocked
0 0 0 0 0 0 0 0 0
minutes
Most time
idling
1.14/min
(OP295)
0.97/min
(OP80)
1.16/min
(OP30)
0.96/min
(OP65)
1.15/min
(OP170)
0.94/min
(OP50)
0.88/min
(OP35)
0.91/min
(OP80)
8.12
minutes