Simulation and Analysis of a Pratt & Whitney
Turbine Module Manufacturing Cell
Christopher L. Gunther
Rensselaer Polytechnic Institute
DSES-6620 Simulation Modeling and Analysis
Final Presentation
21 December 2000
Hartford, Connecticut
Rensselaer Polytechnic Institute
Executive Summary
• Goal: Simulate Manufacturing Cell #6
– Build a ProModel simulation of the system
– Determine the limit production load of the cell
– Identify potential areas for improvement
• Baseline model with current production level
– Verify/validate simulation model
– Understand the process and resource utilization
• Difficult due to long cycle times, shifts, and operators
• Production run results for 7 production levels analyzed
–
–
–
–
Current three-month requirement of 35 parts correlates well
Cell reaches saturation point at around 44 parts/three months
More VTL machines can improve throughput (long operation times)
More operators needed (manual machine and move time)
Rensselaer Polytechnic Institute
Current Process Layout
Standard Work Sheet
Name: Frank Gill, Steve Ali,
Shaun Vickers
FPI - Op. 1330 Cell 3901
Shot Peen - Op. 1350 Cell 3530
Wash - Op. 1360 Cell 3530
Mark - Op. 1380 Cell 3102
Improved Production Process - 52L002
Business Unit:210
Cell:3106
16
Scope of Operati ons:Turn - 1030 to M ark - 1380
VTL - A
VTL - B
Op. 1030
Op. 1040
Setup=0.00
Manual=41.08
1
Setup=0.00
Manual=74.02
Date: 08/07/00
Broach
Op. 1080
2
Setup=0.00
Manual=68.26
5
B
Typhoon
Wash
VTL - D
Op. 1060, 1170
Set up=0 . 0 0
M an ual=9 5 . 19
Set up=0 . 0 0
M an ual=3 3 . 6 8
Op. 1280
15
A
4
VTL - C
10
Setup=0.00
Manual=105.83
3
Op. 1050
Sunstrand 5 Axis
Op. 1130, 1200
Setup=0.00
Manual=27.76
Setup=0.00
Manual=30.90
12
Deburr
13
Op. 1090, 1240
6
Balance
VTL - E
Op. 1250, 1260
1270
14
Pre-Spin process
only
8
9
Abrasive Brush
Turbo - Op. 1100 Cell 3107
Mark - Op. 1120 Cell 3107 7
Operators
Quality Check
Grind - Op. 1150 Cell 3107
11
Safety Precaution
Standard Work in Process
(SWIP)
Machine
Loss of Control
Grind - Op. 1195 Cell 3107
Standard Work in Process
Takt Time (minutes)
Cycle Time
Number of Operators
Part travel distanc e in feet
2
2605.7
3037.47
2
0
Rensselaer Polytechnic Institute
Machine Capacity by Process - Improved
Part Number
Department Number / Name
52L002
3106
Part Name
Required Daily Output
Hub, Turbine Stage 2
Available Time (minutes)
0.4
TAKT Time (minutes)
912
Walk
Time
Manual
Int/Ext
Time
Manual
Internal
Time
Task #
Description Of Task
Machine
PCS. /
Load
1030
Turn
VTL-A
1
0.00
1040
Turn
VTL-B
1
0.00 265.43 191.41
1050
Turn
VTL-C
1060
Turn
1080
1090
52.15
11.07
2605.7
Manual
External
Time
41.08
Auto
Time
Cell
Change
Operator
Over Time Number
Takt Time
(Min)
Takt Time
(Mean)
Takt Time
(Max)
73.10
0.00
B
651.43
390.86
333.66
74.02 250.76
0.00
A
651.43
390.86
333.66
1
0.00 438.73 332.90 105.83 494.86
0.00
A
VTL-D
1
0.00 284.54 189.35
95.19 380.51
0.00
B
Broach
Broach
1
3.26
86.26
18.00
68.26 410.14
0.00
A
Deburr
Bench
1
0.00
36.93
0.00
36.93
0.00
0.00
B
1100
Abrasive Brush
CNC Brush
1
0.00
2.00
2.00
0.00
5.00
5.00
2605.71 1563.43 1334.63
1120
Mark
Dot-Peen
1
0.00
6.82
0.00
6.82
0.00
0.00
2605.71 1563.43 1334.63
1130
Mill
Sundstrand
1
0.00
44.44
16.68
27.76 138.01
0.00
1150
Grind
Heald
1
0.00
75.46
33.35
42.11
33.35
0.00
A
2605.71 1563.43 1334.63
651.43
390.86
333.66
651.43
390.86
333.66
2605.71 1563.43 1334.63
2605.71 1563.43 1334.63
2605.71 1563.43 1334.63
1170
Turn
VTL-D
1
0.00
59.23
25.55
33.68
25.55
0.00
1195
Grind
Pfauter
1
0.00
53.14
33.08
20.06
96.35
0.00
1200
Mill
Sundstrand
1
1.48
59.95
29.05
30.90 128.51
0.00
A
2605.71 1563.43 1334.63
1240
Deburr
Bench
1
0.00 189.52
0.00 189.52
0.00
0.00
B
2605.71 1563.43 1334.63
1250
Balance
Balance
1
0.00
22.09
0.00
22.09
0.00
22.09
B
2605.71 1563.43 1334.63
1260
Balance if necessary
Balance
1
0.00
6.57
2.49
4.08
2.49
6.57
B
2605.71 1563.43 1334.63
1270
Balance if necessary
Balance
1
0.00
22.48
3.05
19.43
3.06
22.48
B
2605.71 1563.43 1334.63
1280
Wash
Proceco
0
0.00
7.43
2.54
4.89
2.54
0.00
B
2605.71 1563.43 1334.63
1330
FPI
FPI
0
0.00
0.00
0.00
0.00
0.00
0.00
2605.71 1563.43 1334.63
1350
Shot Peen
Shot-Peen
0
0.00
24.63
1.00
23.63
75.75
10.00
2605.71 1563.43 1334.63
1360
Wash
Proceco
0
0.00
10.92
5.65
5.27
5.65
0.00
2605.71 1563.43 1334.63
1380
Mark
Dot-Peen
0
0.00
6.82
0.00
6.82
0.00
15.12
2605.71 1563.43 1334.63
4.74
1755.54
897.17
858.37
2125.63
81.26
B
2605.71 1563.43 1334.63
2605.71 1563.43 1334.63
2988.74 Cycle Time
Created by: Frank Gill (5-15-2000)
Rensselaer Polytechnic Institute
Determination of Cell Capability
P re d ic te d v s . A c tu a l P a rts P ro d u c e d
Simulation Parts Produce d
48
43
38
35
33
A v e r a g e Ex its
95% Low
28
9 5 % H ig h
23
18
20
40
60
80
100
P r e d ic t e d P a r t s P r o d u c e d
10 replications
100 replications
3 Month
Req't
Mean
Current
Predicted
35
Min
Mean
Max
21
35
41
50
75
100
Simulation
Average Exits Std. Dev. 95% Low 95% High
33.7
7.3
28.48
38.92
19.69
32.09
36.84
42.1
44.39
44.87
4.24
6.32
4.82
4.03
1.77
1.59
18.82
30.8
35.85
41.28
44.03
44.55
20.56
33.38
37.83
42.92
44.75
45.19
Rensselaer Polytechnic Institute
Simulation Results
M a c h in e % Utiliz a tio n
100
90
VT L A
80
VT L B
70
VT L C
B ro a c h
D e b u rr
50
A b r a s i ve B r u s h
40
5 - A xi s M i l l
G rin d
30
B a la n c e
Wash
20
F P I/P e e n /M a r k
10
0
18
23
28
33
38
43
48
E n tity S ta te s - P a rt 5 2 L 0 0 2
S i m u l a ti o n P a r ts P r o d u c e d (3 m o n th s)
90
80
70
60
Pe rce nt, %
% Utiliza tion
VT L D
60
50
% in M o ve L o g ic
% W a it fo r R e s o u rc e
40
% in O p e ra t io n
% B lo c k e d
30
20
10
0
18
23
28
33
38
S im u la tio n E x its (3 m o n th s )
43
48
Rensselaer Polytechnic Institute
ProModel Simulation
• Manufacturing Cell #6 layout copied
• Machines and operations labeled
– Operator manual internal and external time
– Machine automatic time
– Setup time
• Uncertainty introduced into the model
– 5% normal distributions used on all times
– Random operator downtime
• Gray boxes are queues with counters
• Two operators with idle and downtime locations
• Global variable created to count exits
• DEMO!
Rensselaer Polytechnic Institute