Robert Griffiths
10/17/99
Term Project Proposal
Restate from past homework:
“’Simulation would be useful in the situation facing my business unit currently. Shop
load is decreasing in two of our cells due to out-sourcing, further, plant-wide
redistribution of manpower will occur to cover areas lacking resources. We are currently
planning to combine the two departments forming a single cell with the minimum
necessary machines and people to support anticipated workloads. What are the quantity
and type of machines required given the current part mix? Manpower- what is required in
terms of quantity and ability? These are two obvious questions can simulation can help to
answer.
Presentation of the idea faces steep challenges. The shop environment is one where
"tribal knowledge" and experience frequently clashes with new ideas / methods of
attacking problems. Currently, there is strong pressure to layout the department based
merely on square footage available and perceived capacity requirements. To secure ‘buyin’, I would formulate a conceptual model and demonstrate to management that
variabilities such as downtimes, operator resources, schedule peaks, etc., are not taken
into account in our current practice. A disciplined simulation approach of planning, data
collection, cell model, and validation can increase the chance of success that we make a
successful transition.
Cell leaders and part schedulers would be critical in the development of such a model.
They could provide historical information for model development as well as validation.’”
A layout of the proposed department would have approximately 13 locations (within the
cell). Machine types vary from lathes, milling centers, deburr booths, layout tables, etc.,.
Approximately 17 operators can serve as resources, some with duplicate abilities, others
with special capabilities. 3 part numbers (entities) will be produced by the cell- the
F119, JT8, and 229A inlet cases.
Although part arrival (per MRP) data is accessible, accurate data for machine downtime
and general non-production activities (ie., communication meetings, process problems
resulting in workstops, etc.,) will be difficult to quantify.
As stated above the goals of the simulation / study would be to:
1) Examine the machine loading for the anticipated part mix.
2) Understand how many machinists are required and if additional training must occur to
cover required skills.
3) Project how cycle-time reductions (through process improvements) may affect cell
flow.