Toy Airplane Manufacturing
Mini Project
Christian Mickelson
Ted Pelzer
Todd Madole
IE 4235
Case Study 1: Toy Airplane Manufacturing
A toy company produces three types (A,B and C) of a toy aluminum airplanes in the following daily
volumes: A=1000 B=1500 and C=1800. The company expects demand to increase for its products 30
percent over the next six months and needs to know the total machines, AGV’s and operators that will be
required. All planes go through five operations except for plane A, which skips the cutting operation.
Following is a list of operation times, move times and resources used:
Opn
Description
Operation Time
Resource
10 Die Casting
3 min (outputs 6 parts)
Automated die caster.3 min
20 Cutting
Triangular(.25,.28,.35)
Cutter
30 Grinding
Sample Times: .23 .22 .26 .22 Grinder
.25 .23 .24 .22 .21 .23 .20 .23
.22 .25 .23 .24 .23 .25 .47 .23
.25 .21 .24 .22 .26 .23 .25 .24
.21 .24 .26
.2 min
40 Coating
12 min per batch of 24
Coater
.2min
Packager
exits with 88% yield
50 Inspection and Packaging Triangular(.27,.30,.40)
Move Logic
none
After die casting, planes are moved to each operation in batch sizes of 24. Input buffers exist at each
operation. The factory operates eight hours a day, five days per week. The factory starts out empty at the
beginning of each day and ships all parts produced at the end of the day. The die caster experiences
downtime every 30 minutes exponentially distributed and takes 8 minutes normally distributed with a
standard deviation of 2 minutes to repair. One maintenance person is always on duty to make repairs.
Model Building and Assumptions:
The .47 grinding time was ignored in the data set because it is a statistical outlier that does not fit
the rest of the data. It can be assumed that this time was caused do to some non- regular operating error.
It was also assumed that the AGVs move the appropriate speed and distances required for the given move
times. Batches consist of 24 planes of the same type. Operation times are the same for each type of plane
and any change over in tooling is also assumed in the operation time. Each machine requires at least one
operator. Additional operators would be required depending on how the company applies benefits and
break times. Each simulation model also includes a system that reorders more raw materials when 6
planes are added to scrap.
As-Is Model
First an as-is model was constructed for the facility. Initially, the team viewed operation times and found
that the die caster seemed to be a bottleneck operation. The team used Calculation 1 to find the minimum
number of machines needed to meet demand.
Deterministic Modeling:
(Assuming worst case scenario for operation times)
Cutter:
.35 min * 4300 planes = 1505 minutes required
1505 minutes/480 minutes in a day = 3.1 machines => 4 Cutting machines
Grinding:
.27 min * 4300 planes = 1161
minutes /480 minutes in a day = 2.4 => 3 Grinding machines
Coating:
3300 planes / 24 per batch = 138 batches
12min * 138 batches = 1656
minutes / 480 minutes in a day = 3.45 => 4 Coating Machines
Inspect & Package:
.4 min * 4300 planes = 1720 minutes
1720
minutes / 480 minutes in a day = 3.6 => 4 Inspect & Package stations
Die Caster:
4300 planes/6 planes per cast = 717 raw material entities to die casting
717 raw material entities * 3 minute operation time = 2151 minutes
2151min / 480 minutes
in a day = 4.5 machine => 5 die casting machines needed (assuming no downtimes)
Each of the calculations does not include downtimes. This is why the calculations do not match the exact
number actually used in the simulation.
The following is a list of the equipment needed to produce the as-is quantities of toy airplanes:
Resource
Die Caster
Cutter
Grinder
Coater
Packager
AGV
Mechanic
Quantity
8
4
3
5
2
Average Utilization
63.67%
74.49%
78.47%
78.00%
82.10%
3
3
6.08%
42.58%
Chart 1
The die caster had to be increased to 8 units due to the high amount of downtime. The die casters were
down an average of 16.72% of the time. Each Plane A spent 12.5 minutes in the system. Plane B and
Plane C took 22.58 min and 22.22 min respectively.
An important part of this model to reduce bottle necks was how the planes arrived to the system. Since
only planes B and C went through the coating process it was best to alternate them. The group set arrivals
so that planes would arrival at 9 minute intervals. This was done because it took 3 minute per part at the
die caster so a different part arrived every 3 minutes to the system. By doing this it reduced blocking at the
coater and helped to reduce the number needed.
It was determined that the 3 AGVs needed would each travel on their own network. A comparison model
was run with 3 AGVs and one path network. One path network and three separate path networks
produced the same amount of planes during an 8 hour day. The team chose 3 separate networks to reduce
the wear and tear on the AGVs. 3 separate paths would also be safer than 1 path that traverses the whole
facility. The total area covered by the 3 separate paths would be fractional compared to 1 path. This will
also keep the AGV’s in their own zones to avoid the possibility of collisions 3 AGVs were needed
regardless of the type of path network. 2 AGVs in one path network produced 87 fewer planes than
needed. A chart of these pros and cons is listed below:
1-Path Network
3-Path network
Utilization % Notes:
30.40% Less safe, more area is
covered
8.01% More Safe, small area
covered. Also no
collisions possible
Chart 2
To-Be Model; Using specifications of Case Study
The new manufacturing system expects a 30% increase in production. More machines were added to the
system to account for the increased demand.
The chart below shows the new quantities and utilization percentages:
Resource
Die Caster
Cutter
Grinder
Coater
Packager
AGV
Mechanic
Quantity
Change
10
5
4
6
3
+2
+1
+1
+1
+1
Average Utilization
67.12%
78.22%
77.46%
84.89%
71.58%
3
3
0
0
8.01%
63.42%
Chart 3
Two machines were added for die casting to account for the excessive downtimes. The average down time
for the die casters in the new model was 21.69%. One machine was added to each of the other processes
to keep up with the increased demand. The AGVs and mechanics remain unchanged while each of their
utilization percentages increases.
To-Be; Creative Solution
To reach 30% increase in production, the facility can easily increase the amount of machines; however the
group found many inefficiencies in the process.
If downtime occurs every 120 minutes rather than 30 minutes, the die casters can meet the new production
requirements. The group suggests that the die casters be modified to be more reliable rather than
purchasing more die casters at an increased cost.
The system only has an 88% yield. This means that 12 out of every 100 planes is a defect. Increasing the
yield to 3 sigma levels reduced the amount of scrap produced from 805 planes to 63 planes in 8 hours of
production. If the system is able to increase quality to 3 Sigma and the downtimes are reduced to every 2
hours, only 1 grinder needs to be added while the mechanics can be reduced to only 1. Chart 3 shows
required numbers for a more efficient FMS:
Resource
Die Caster
Cutter
Grinder
Coater
Packager
AGV
Mechanic
Quantity
8
4
4
5
2
Change
-2
-1
0
-1
-1
Average Utilization
74.30%
86.89%
68.79%
90.36%
94.61%
3
1
0
-2
7.15%
42.36%
Chart 4
Conclusion:
The group suggests that the creative solution be implemented in this case study. Increasing the efficiency
of the facility will require the purchase of only 1 new grinder to keep up with demand. The increased
efficiency will also reduce the mechanics needed to only 1 reducing work force costs. It is more important
to add efficient machines that produce quality parts than to add more machines to the system to meet
demand. Reducing the overall number of machines in the facility and increasing quality will reduce
machine costs, workforce costs, material costs and WIP.
Appendix
General Report: As-Is Model Output
-------------------------------------------------------------------------------General Report
Output from C:\DOCUME~1\mado0012\Desktop\PLANET~2.MOD
Date: Dec/05/2006
Time: 09:30:27 AM
-------------------------------------------------------------------------------Scenario
: Normal Run
Replication
: 1 of 1
Simulation Time : 8 hr
-------------------------------------------------------------------------------LOCATIONS
Average
Location
Scheduled
Total
Minutes
Average
Maximum
Current
Name
Hours Capacity Entries Per Entry Contents Contents Contents
--------------- --------- -------- ------- --------- -------- -------- -------Die Casting.1
8
1
114
3.00
0.71
1
0
Die Casting.2
8
1
109
3.00
0.68
1
0
Die Casting.3
8
1
93
3.00
0.58
1
0
Die Casting.4
8
1
104
3.00
0.65
1
0
Die Casting.5
8
1
98
3.00
0.61
1
0
Die Casting.6
8
1
104
3.00
0.65
1
0
Die Casting.7
8
1
94
3.00
0.58
1
0
Die Casting.8
8
1
99
3.00
0.61
1
0
Die Casting
64
8
815
3.00
0.63
8
0
Cutting.1
8
1
1218
0.29
0.74
1
0
Cutting.2
8
1
1217
0.29
0.74
1
0
Cutting.3
8
1
1220
0.29
0.74
1
0
Cutting.4
8
1
1217
0.29
0.74
1
0
Cutting
32
4
4872
0.29
0.74
4
0
Grinder.1
8
1
1627
0.23
0.78
1
0
Grinder.2
8
1
1624
0.23
0.78
1
0
Grinder.3
8
1
1621
0.23
0.78
1
0
Grinder
24
3
4872
0.23
0.78
3
0
Coater.1
8
1
33
12.00
0.82
1
0
Coater.2
8
1
32
12.00
0.8
1
0
Coater.3
8
1
31
12.00
0.77
1
0
Coater.4
8
1
30
12.00
0.75
1
0
Coater.5
8
1
30
12.00
0.75
1
0
Coater
40
5
156
12.00
0.78
5
0
IandP.1
8
2
2436
0.32
1.64
2
0
IandP.2
8
2
2436
0.32
1.64
2
0
IandP
16
4
4872
0.32
1.64
4
0
RM storage
8
999999
815
25.12
42.66
104
0
Cutting buffer
8
999999
203
2.47
1.04
4
0
Grinding buffer
8
999999
203
2.74
1.16
3
0
Coating buffer
8
999999
156
5.07
1.64
12
0
IandPconv
8
999999
203
3.72
1.57
5
0
Batch1
8
72
4890
2.48
25.27
72
18
Batch2
8
72
4872
0.88
8.97
26
0
Batch4
8
72
4872
0.81
8.30
25
0
Scrap
8
999999
572
0.0
0
1
0
LOCATION STATES BY PERCENTAGE (Multiple Capacity)
%
|
Location
Scheduled
% Partially
%
Name
Hours
Empty
Occupied
Full
--------------- --------- ------ --------- ----IandP.1
8
17.58
0.51 81.90
IandP.2
8
17.67
0.58 81.75
IandP
16
17.63
0.55 81.83
RM storage
8
24.05
75.95
0.0
Cutting buffer
8
28.18
71.82
0.0
Grinding buffer
8
22.85
77.15
0.0
Coating buffer
8
70.39
29.61
0.0
IandPconv
8
18.82
81.18
0.0
Batch1
8
1.73
98.23
0.04
Batch2
8
25.60
74.40
0.0
Batch4
8
31.22
68.78
0.0
Scrap
8 100.00
0.0
0.0
|
%
| Down
| ---| 0.0
| 0.0
| 0.0
| 0.0
| 0.0
| 0.0
| 0.0
| 0.0
| 0.0
| 0.0
| 0.0
| 0.0
LOCATION STATES BY PERCENTAGE (Single Capacity/Tanks)
Location
Scheduled
%
%
%
%
%
%
% Util
-----71.25
68.12
58.12
65.00
61.25
65.00
58.75
61.88
63.67
74.50
74.46
74.57
74.44
74.49
78.50
78.51
78.40
78.47
82.50
80.00
77.50
75.00
75.00
78.00
82.16
82.04
82.10
0.0
0.0
0.0
0.0
0.0
35.10
12.46
11.53
0.0
Name
------------Die Casting.1
Die Casting.2
Die Casting.3
Die Casting.4
Die Casting.5
Die Casting.6
Die Casting.7
Die Casting.8
Die Casting
Cutting.1
Cutting.2
Cutting.3
Cutting.4
Cutting
Grinder.1
Grinder.2
Grinder.3
Grinder
Coater.1
Coater.2
Coater.3
Coater.4
Coater.5
Coater
Hours
--------8
8
8
8
8
8
8
8
64
8
8
8
8
32
8
8
8
24
8
8
8
8
8
40
Operation
--------71.25
68.13
58.13
65.00
61.25
65.00
58.75
61.88
63.67
74.50
74.46
74.57
74.44
74.49
78.50
78.51
78.40
78.47
82.50
80.00
77.50
75.00
75.00
78.00
Setup
----0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
Idle
----14.99
19.64
20.30
20.51
20.17
20.36
19.74
21.11
19.60
25.50
25.54
25.43
25.56
25.51
21.50
21.49
21.60
21.53
17.50
20.00
22.50
25.00
25.00
22.00
Waiting
------0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.01
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
Blocked
------0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
Down
----13.76
12.23
21.57
14.49
18.58
14.64
21.51
17.01
16.72
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
RESOURCES
Resource
Name
------------Die to Cut
Grind to Coat
Coat to IP
Maitenance.1
Maitenance.2
Maitenance.3
Maitenance
Units
----1
1
1
1
1
1
3
Scheduled
Hours
--------8
8
8
8
8
8
24
Number
Of Times
Used
-------203
203
156
35
28
16
79
Average
Minutes
Per
Usage
------0.08
0.25
0.11
7.91
7.24
7.77
7.64
Average
Minutes
Travel
To Use
------0.0
0.0
0.0
0.11
0.11
0.10
0.11
Average
Minutes
Travel
To Park
------0.08
0.25
0.11
0.13
0.13
0.13
0.13
% Blocked
In Travel
--------0.0
0.0
0.0
0.0
0.0
0.0
0.0
RESOURCE STATES BY PERCENTAGE
Resource
Name
------------Die to Cut
Grind to Coat
Coat to IP
Maitenance.1
Maitenance.2
Maitenance.3
Maitenance
Scheduled
Hours
--------8
8
8
8
8
8
24
%
In Use
-----3.72
10.61
3.77
57.68
42.28
25.92
41.96
%
Travel
To Use
-----0.13
0.0
0.0
0.83
0.67
0.36
0.62
%
Travel
To Park
------3.59
10.61
3.77
0.83
0.67
0.36
0.62
%
Idle
----92.56
78.79
92.46
40.66
56.39
73.36
56.80
Average
Minutes
In
System
------37.98
57.85
57.15
-
Average
Minutes
In Move
Logic
------0.64
0.37
0.36
-
Average
Minutes
Wait For
Res, etc.
--------7.93
6.28
5.92
-
%
Down
---0.0
0.0
0.0
0.0
0.0
0.0
0.0
FAILED ARRIVALS
Entity
Name
------------Raw MaterialA
Raw MaterialB
Raw MaterialC
Location
Name
---------RM storage
RM storage
RM storage
Total
Failed
-----0
0
0
ENTITY ACTIVITY
Entity
Name
------------PlaneA
PlaneB
PlaneC
Raw MaterialA
Raw MaterialB
Raw MaterialC
Total
Exits
----1002
1495
1803
0
0
0
Current
Quantity
In System
--------6
12
0
0
0
0
Average
Minutes
In
Operation
--------3.92
15.92
15.92
-
Average
Minutes
Blocked
------25.48
35.27
34.93
-
% Util
-----3.85
10.61
3.77
58.51
42.95
26.28
42.58
Junk
572
0
ENTITY STATES BY PERCENTAGE
%
%
Entity
In Move
Wait For
Name
Logic Res, etc.
------------- ------- --------PlaneA
1.70
20.88
PlaneB
0.64
10.87
PlaneC
0.64
10.37
Raw MaterialA
Raw MaterialB
Raw MaterialC
Junk
0.84
11.95
51.29
0.43
%
In Operation
-----------10.33
27.52
27.86
25.89
6.13
13.28
31.45
%
Blocked
------67.08
60.96
61.12
61.32
General Report: To-Be Model Output
-------------------------------------------------------------------------------General Report
Output from C:\DOCUME~1\mado0012\Desktop\PLANET~1.MOD
Date: Dec/05/2006
Time: 09:29:53 AM
-------------------------------------------------------------------------------Scenario
: Normal Run
Replication
: 1 of 1
Simulation Time : 8 hr
-------------------------------------------------------------------------------LOCATIONS
Average
Location
Scheduled
Total
Minutes
Average
Maximum
Current
Name
Hours Capacity Entries Per Entry Contents Contents Contents
--------------- --------- -------- ------- --------- -------- -------- -------Die Casting.1
8
1
119
3.00
0.74
1
0
Die Casting.2
8
1
112
3.00
0.7
1
0
Die Casting.3
8
1
105
3.00
0.65
1
0
Die Casting.4
8
1
117
3.00
0.73
1
0
Die Casting.5
8
1
104
3.00
0.65
1
0
Die Casting.6
8
1
95
3.00
0.59
1
0
Die Casting.7
8
1
110
3.00
0.68
1
0
Die Casting.8
8
1
101
3.00
0.63
1
0
Die Casting.9
8
1
103
3.00
0.64
1
0
Die Casting.10
8
1
108
3.00
0.67
1
0
Die Casting
80
10
1074
3.00
0.67
10
0
Cutting.1
8
1
1282
0.29
0.78
1
0
Cutting.2
8
1
1283
0.29
0.78
1
0
Cutting.3
8
1
1279
0.29
0.78
1
0
Cutting.4
8
1
1279
0.29
0.78
1
0
Cutting.5
8
1
1285
0.29
0.78
1
0
Cutting
40
5
6408
0.29
0.78
5
0
Grinder.1
8
1
1602
0.23
0.77
1
0
Grinder.2
8
1
1601
0.23
0.77
1
0
Grinder.3
8
1
1602
0.23
0.77
1
0
Grinder.4
8
1
1603
0.23
0.77
1
0
Grinder
32
4
6408
0.23
0.77
4
0
Coater.1
8
1
37
12.00
0.92
1
0
Coater.2
8
1
36
11.91
0.89
1
1
Coater.3
8
1
35
12.00
0.87
1
0
Coater.4
8
1
34
12.00
0.85
1
0
Coater.5
8
1
33
12.00
0.82
1
0
Coater.6
8
1
29
12.00
0.72
1
0
Coater
48
6
204
11.98
0.84
6
1
IandP.1
8
2
2132
0.32
1.43
2
0
IandP.2
8
2
2128
0.32
1.43
2
0
IandP.3
8
2
2124
0.32
1.42
2
0
IandP
24
6
6384
0.32
1.43
6
0
RM storage
8
200
1074
42.56
95.25
178
0
Cutting buffer
8
999999
267
1.95
1.09
4
0
Grinding buffer
8
999999
267
1.23
0.68
2
0
Coating buffer
8
999999
204
7.54
3.20
17
0
IandPconv
8
999999
266
1.56
0.86
3
0
Batch1
8
72
6444
1.85
24.90
60
36
Batch2
8
72
6408
0.63
8.44
24
0
Batch4
8
72
6408
0.66
8.89
25
0
Scrap
8
999999
805
0.0
0
1
0
OCATION STATES BY PERCENTAGE (Multiple Capacity)
%
|
% Util
-----74.38
70.00
65.62
73.12
65.00
59.38
68.75
63.12
64.38
67.50
67.12
78.31
78.08
78.20
78.17
78.32
78.22
77.33
77.63
77.30
77.60
77.46
92.50
89.36
87.50
85.00
82.50
72.50
84.89
71.58
71.67
71.50
71.58
47.63
0.0
0.0
0.0
0.0
34.58
11.73
12.36
0.0
Location
Scheduled
% Partially
% |
%
Name
Hours
Empty
Occupied
Full | Down
--------------- --------- ------ --------- ----- | ---IandP.1
8
27.26
2.32 70.42 | 0.0
IandP.2
8
27.23
2.19 70.58 | 0.0
IandP.3
8
27.36
2.28 70.36 | 0.0
IandP
24
27.28
2.27 70.45 | 0.0
RM storage
8
14.48
85.52
0.0 | 0.0
Cutting buffer
8
25.32
74.68
0.0 | 0.0
Grinding buffer
8
31.48
68.52
0.0 | 0.0
Coating buffer
8
64.00
36.00
0.0 | 0.0
IandPconv
8
33.74
66.26
0.0 | 0.0
Batch1
8
2.39
97.61
0.0 | 0.0
Batch2
8
30.97
69.03
0.0 | 0.0
Batch4
8
26.52
73.48
0.0 | 0.0
Scrap
8 100.00
0.0
0.0 | 0.0
LOCATION STATES BY PERCENTAGE (Single Capacity/Tanks)
Location
Name
-------------Die Casting.1
Die Casting.2
Die Casting.3
Die Casting.4
Die Casting.5
Die Casting.6
Die Casting.7
Die Casting.8
Die Casting.9
Die Casting.10
Die Casting
Cutting.1
Cutting.2
Cutting.3
Cutting.4
Cutting.5
Cutting
Grinder.1
Grinder.2
Grinder.3
Grinder.4
Grinder
Coater.1
Coater.2
Coater.3
Coater.4
Coater.5
Coater.6
Coater
Scheduled
Hours
--------8
8
8
8
8
8
8
8
8
8
80
8
8
8
8
8
40
8
8
8
8
32
8
8
8
8
8
8
48
%
Operation
--------74.38
70.00
65.63
73.13
65.00
59.38
68.75
63.13
64.38
67.50
67.13
78.31
78.08
78.20
78.17
78.32
78.22
77.33
77.63
77.30
77.60
77.46
92.50
89.36
87.50
85.00
82.50
72.50
84.89
%
Setup
----0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
%
Idle
----5.05
9.76
10.32
12.64
13.15
10.75
13.05
11.77
12.79
12.56
11.18
21.69
21.92
21.80
21.83
21.68
21.78
22.67
22.37
22.70
22.40
22.54
7.50
10.64
12.50
15.00
17.50
27.50
15.11
%
Waiting
------0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
%
Blocked
------0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
%
Down
----20.57
20.24
24.05
14.23
21.85
29.87
18.20
25.10
22.83
19.94
21.69
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
Average
Minutes
Per
Usage
------0.08
0.25
0.11
8.98
8.81
7.69
8.53
Average
Minutes
Travel
To Use
------0.0
0.0
0.0
0.08
0.07
0.06
0.07
Average
Minutes
Travel
To Park
------0.08
0.25
0.11
0.13
0.13
0.13
0.13
% Blocked
In Travel
--------0.0
0.0
0.0
0.0
0.0
0.0
0.0
RESOURCES
Resource
Name
------------Die to Cut
Grind to Coat
Coat to IP
Maitenance.1
Maitenance.2
Maitenance.3
Maitenance
Units
----1
1
1
1
1
1
3
Scheduled
Hours
--------8
8
8
8
8
8
24
Number
Of Times
Used
-------267
267
203
37
37
32
106
RESOURCE STATES BY PERCENTAGE
Resource
Name
------------Die to Cut
Grind to Coat
Coat to IP
Maitenance.1
Maitenance.2
Maitenance.3
Scheduled
Hours
--------8
8
8
8
8
8
%
In Use
-----4.90
14.04
4.91
69.29
67.95
51.31
%
Travel
To Use
-----0.18
0.0
0.0
0.67
0.61
0.44
%
Travel
To Park
------4.71
14.04
4.91
0.67
0.61
0.44
%
Idle
----90.21
71.91
90.19
29.38
30.83
47.81
%
Down
---0.0
0.0
0.0
0.0
0.0
0.0
% Util
-----5.08
14.04
4.91
69.95
68.56
51.75
63.42
Maitenance
24
FAILED ARRIVALS
Entity
Location
Name
Name
------------- ---------Raw MaterialA RM storage
Raw MaterialB RM storage
Raw MaterialC RM storage
ENTITY ACTIVITY
Entity
Name
------------PlaneA
PlaneB
PlaneC
Raw MaterialA
Raw MaterialB
Raw MaterialC
Junk
ENTITY STATES
Entity
Name
------------PlaneA
PlaneB
PlaneC
Raw MaterialA
Raw MaterialB
Raw MaterialC
Junk
62.85
0.57
36.01
Average
Minutes
In
System
------49.70
73.75
74.13
67.56
Average
Minutes
In Move
Logic
------0.64
0.36
0.37
0.43
0.0
Total
Failed
-----0
0
0
Current
Total
Quantity
Exits In System
----- --------1325
6
1932
37
2322
18
0
0
0
0
0
0
805
0
BY PERCENTAGE
%
In Move
Logic
------1.30
0.50
0.50
0.64
0.57
%
Wait For
Res, etc.
--------10.18
4.82
4.89
5.53
%
In Operation
-----------7.89
21.59
21.48
19.44
Average
Minutes
Wait For
Res, etc.
--------5.05
3.55
3.62
3.73
Average
Minutes
In
Operation
--------3.92
15.92
15.92
13.13
Average
Minutes
Blocked
------40.07
53.90
54.22
50.26
%
Blocked
------80.63
73.09
73.14
74.39
Formatted Listing of To-Be Model
********************************************************************************
*
*
*
Formatted Listing of Model:
*
*
C:\temp\planetrialdowntime.MOD
*
*
*
********************************************************************************
Time Units:
Distance Units:
Minutes
Feet
********************************************************************************
*
Locations
*
********************************************************************************
Name
--------------Die_Casting
Die_Casting.1
Die_Casting.2
Die_Casting.3
Die_Casting.4
Die_Casting.5
Die_Casting.6
Die_Casting.7
Die_Casting.8
Cutting
Cutting.1
Cutting.2
Cutting.3
Cutting.4
Grinder
Grinder.1
Grinder.2
Grinder.3
Grinder.4
Coater
Coater.1
Coater.2
Coater.3
Cap
-------1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Units
----8
1
1
1
1
1
1
1
1
4
1
1
1
1
4
1
1
1
1
5
1
1
1
Stats
----------Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Rules
Cost
--------------- -----------Oldest, , First
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, , First
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, , First
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, ,
Oldest, , First
Oldest, ,
Oldest, ,
Oldest, ,
Coater.4
Coater.5
IandP
IandP.1
IandP.2
RM_storage
Cutting_buffer
Grinding_buffer
Coating_buffer
IandPconv
Batch1
Batch2
Batch4
Scrap
1
1
2
2
2
500
inf
inf
inf
INFINITE
72
72
72
inf
1
1
2
1
1
1
1
1
1
1
1
1
1
1
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Time
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Series
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
Oldest,
,
,
, First
,
,
,
,
,
,
FIFO,
,
,
,
,
********************************************************************************
*
Usage downtimes for Locations
*
********************************************************************************
Loc
Frequency
First Time
Priority
Logic
------------- ------------ ------------ ------------ -----------------Die_Casting
E(120) Min
99
GET 1 Maitenance
WAIT N(8, 2)
FREE Maitenance
Die_Casting.1 E(120) Min
99
GET 1 Maitenance
WAIT N(8, 2)
FREE Maitenance
Die_Casting.2 E(120) Min
99
GET 1 Maitenance
WAIT N(8, 2)
FREE Maitenance
Die_Casting.3 E(120) Min
99
GET 1 Maitenance
WAIT N(8, 2)
FREE Maitenance
Die_Casting.4 E(120) Min
99
GET 1 Maitenance
WAIT N(8, 2)
FREE Maitenance
Die_Casting.5 E(120) Min
99
GET 1 Maitenance
WAIT N(8, 2)
FREE Maitenance
Die_Casting.6 E(120) Min
99
GET 1 Maitenance
WAIT N(8, 2)
FREE Maitenance
Die_Casting.7 E(120) Min
99
GET 1 Maitenance
WAIT N(8, 2)
FREE Maitenance
Die_Casting.8 E(120) Min
99
GET 1 Maitenance
WAIT N(8, 2)
FREE Maitenance
********************************************************************************
*
Entities
*
********************************************************************************
Name
------------PlaneA
PlaneB
PlaneC
Raw_MaterialA
Raw_MaterialB
Raw_MaterialC
Junk
Speed (fpm)
-----------150
150
150
150
150
150
150
Stats
Cost
----------- -----------Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
Time Series
********************************************************************************
*
Path Networks
*
********************************************************************************
Name
Type
T/S
From
To
BI
Dist/Time Speed Factor
-------- ----------- ---------------- -------- -------- ---- ---------- ------------
Path1
Path3
Passing
Passing
Path4
Repair
Passing
Passing
Speed & Distance N1
Speed & Distance N1
N1
Speed & Distance N1
Speed & Distance N1
N2
N2
N3
N2
N2
Bi
Bi
Bi
Bi
Bi
13.33
24.14
82.93
17.43
19.98
1
1
1
1
1
********************************************************************************
*
Interfaces
*
********************************************************************************
Net
Node
---------- ---------Path1
N1
N2
Path3
N1
N2
N3
Path4
N1
N2
Repair
N2
Location
-------------Batch1
Cutting_buffer
Batch2
Coating_buffer
IandPconv
Coater
IandPconv
Die_Casting
********************************************************************************
*
Resources
*
********************************************************************************
Res
Name
Units Stats
Search
------------- ----- -------- ------Die_to_Cut
1
By Unit Closest
Ent
Search Path
------ ---------Oldest Path1
Home: N1
(Return)
Motion
Cost
-------------- -----------Empty: 150 fpm
Full: 150 fpm
Grind_to_Coat 1
By Unit
Closest Oldest Path3
Home: N1
(Return)
Empty: 150 fpm
Full: 150 fpm
Coat_to_IP
1
By Unit
Closest Oldest Path4
Home: N1
(Return)
Empty: 150 fpm
Full: 150 fpm
Maitenance
1
By Unit
Closest Oldest Repair
Home: N1
(Return)
Empty: 150 fpm
Full: 150 fpm
********************************************************************************
*
Processing
*
********************************************************************************
Process
Entity
Location
Operation
------------- --------------- -----------------Raw_MaterialA RM_storage
WAIT 0
Routing
Blk Output
Destination
Rule
---- ------------- --------------- ---------1
Raw_MaterialA Die_Casting
PlaneA
PlaneA
PlaneA
PlaneA
PlaneA
PlaneA
1
PlaneA
1
PlaneA
1
PlaneA
WAIT T(.25, .28, .35) MIN
1
PlaneA
Grinding_buffer UNGROUP
1
PlaneA
Grinding_buffer
1
PlaneA
Grinder
WAIT T(.196, .23, .27) MIN
Cutting_buffer
Cutting_buffer
Cutting
IandPconv
IandPconv
IandP
Raw_MaterialB Die_Casting
FIRST 1
Batch1
Cutting
Cutting
FIRST 6
FIRST 1
FIRST 1
Batch4
Grinder
Grinder
FIRST 1
FIRST 1
FIRST 1
PlaneA
Batch2
FIRST 1
PlaneA
PlaneA
IandP
IandP
FIRST 1
FIRST 1
PlaneA
PlaneA
EXIT
Scrap
0.989000 1
0.011000
PlaneB
Batch1
FIRST 6
UNGROUP
1
PlaneA
PlaneA
PlaneA
Raw_MaterialA Die_Casting
WAIT 3 MIN
UNGROUP
1
1
WAIT T(.27,.30,.40) MIN
1
WAIT 3 MIN
1
Move Logic
------------
Raw_MaterialC
PlaneB
PlaneB
PlaneC
PlaneC
PlaneB
Die_Casting
Cutting_buffer
Cutting_buffer
Cutting_buffer
Cutting_buffer
Cutting
PlaneC
Cutting
PlaneB
PlaneB
PlaneC
PlaneC
PlaneB
Grinding_buffer
Grinding_buffer
Grinding_buffer
Grinding_buffer
Grinder
PlaneC
Grinder
PlaneB
Coating_buffer
PlaneC
Coating_buffer
PlaneB
Coater
FOR .2 MIN THEN FREE
WAIT 3 MIN
UNGROUP
UNGROUP
1
1
1
1
1
PlaneC
PlaneB
PlaneB
PlaneC
PlaneC
WAIT T(.25, .28, .35) MIN
1
PlaneB
WAIT T(.25, .28, .35) MIN
1
PlaneC
UNGROUP
1
PlaneB
1
PlaneB
UNGROUP
1
PlaneC
1
PlaneC
WAIT T(.196, .23, .27) MIN
1
PlaneB
WAIT T(.196, .23, .27) MIN
1
PlaneC
1
PlaneB
1
PlaneC
WAIT 12 MIN
1
PlaneB
PlaneB
PlaneB
PlaneC
PlaneC
PlaneB
IandPconv
IandPconv
IandPconv
IandPconv
IandP
UNGROUP
PlaneC
IandP
WAIT T(.27,.30,.40)
UNGROUP
Batch1
Cutting
Cutting
Cutting
Cutting
FIRST
FIRST
FIRST
FIRST
FIRST
6
1
1
1
1
Batch4
FIRST 1
Batch4
Grinder
Grinder
Grinder
Grinder
FIRST
FIRST
FIRST
FIRST
FIRST
Batch2
FIRST 1
Batch2
Coater
Coater
IandPconv
FIRST
FIRST
FIRST
FIRST
1
1
1
1
1
1
1
1
1
1
1
1
1
MOVE WITH Coat_to_IP
1
1
1
1
PlaneB
PlaneB
PlaneC
PlaneC
IandP
IandP
IandP
IandP
FIRST
FIRST
FIRST
FIRST
1
PlaneB
PlaneB
EXIT
Scrap
0.989000 1
0.011000
1
EXIT
Scrap
IandPconv
0.989000 1
0.011000
FIRST 1
MOVE WITH Coat_to_IP
FIRST 1
MOVE WITH Die_to_Cut
WAIT T(.27,.30,.40)
PlaneC
Coater
FOR .2 MIN THEN FREE
WAIT 12 MIN
1
PlaneC
PlaneC
PlaneC
PlaneA
Batch1
FOR .3 MIN THEN FREE
PlaneA
Batch4
PlaneA
Batch2
FOR .2 MIN THEN FREE
PlaneB
Batch1
FOR .3 MIN THEN FREE
PlaneC
Batch1
FOR .3 MIN THEN FREE
PlaneB
Batch4
PlaneC
Batch4
PlaneB
Batch2
FOR .2 MIN THEN FREE
PlaneC
Batch2
FOR .2 MIN THEN FREE
Raw_MaterialB RM_storage
Raw_MaterialC RM_storage
PlaneA
Scrap
GROUP 24
1
PlaneA
Cutting_buffer
GROUP 24
GROUP 24
1
1
PlaneA
PlaneA
Grinding_buffer FIRST 1
IandPconv
FIRST 1
MOVE WITH Grind_to_Coat
Group 24
1
PlaneB
Cutting_buffer
FIRST 1
MOVE WITH Die_to_Cut
GROUP 24
1
PlaneC
Cutting_buffer
FIRST 1
MOVE WITH Die_to_Cut
GROUP 24
GROUP 24
GROUP 24
1
1
1
PlaneB
PlaneC
PlaneB
Grinding_buffer FIRST 1
Grinding_buffer FIRST 1
Coating_buffer FIRST 1
MOVE WITH Grind_to_Coat
GROUP 24
1
PlaneC
Coating_buffer
MOVE WITH Grind_to_Coat
1
1
Raw_MaterialB Die_Casting
Raw_MaterialC Die_Casting
PlaneB
Scrap
PlaneC
Scrap
INC CounterA
If CounterA = 6 THEN
{
Order 1 Raw_MaterialA TO RM_storage
CounterA = 0
}
1
Junk
INC CounterB
If CounterB = 6 THEN
{
Order 1 Raw_MaterialB TO RM_storage
CounterB = 0
}
1
Junk
INC CounterC
If CounterC = 6 THEN
{
Order 1 Raw_MaterialC TO RM_storage
CounterC = 0
}
1
Junk
FIRST 1
FIRST 1
FIRST 1
EXIT
FIRST 1
EXIT
FIRST 1
EXIT
FIRST 1
********************************************************************************
*
Arrivals
*
********************************************************************************
Entity
Location
Qty each
First Time Occurrences Frequency Logic
------------- ---------- ---------- ---------- ----------- ---------- ------------
Raw_MaterialA RM_storage 6
Raw_MaterialB RM_storage 8
Raw_MaterialC RM_storage 10
3
6
37
41
39
N(6, .01)
N(9, .01)
N(9, .01)
********************************************************************************
*
Attributes
*
********************************************************************************
ID
Type
Classification
---------- ------------ -------------type
Integer
Entity
********************************************************************************
*
Variables (global)
*
********************************************************************************
ID
---------CounterA
CounterB
CounterC
Type
-----------Integer
Integer
Integer
Initial value
------------0
0
0
Stats
----------None
None
None
********************************************************************************
*
User Distributions
*
********************************************************************************
ID
Type
Cumulative
Percentage
--------------- ------------ ------------ -----------Rawmaterialtype Discrete
No
23.26
34.88
41.86
Value
-----------1
2
3
General Report: To-Be Creative Solution Model Output
-------------------------------------------------------------------------------General Report
Output from C:\DOCUME~1\labauth\LOCALS~1\TEMPOR~1\Content.IE5\S76I0E74\PLANET~1.MOD
Date: Dec/12/2006
Time: 08:41:25 AM
-------------------------------------------------------------------------------Scenario
: Normal Run
Replication
: 1 of 1
Simulation Time : 8 hr
-------------------------------------------------------------------------------LOCATIONS
Location
Name
--------------Die Casting.1
Die Casting.2
Die Casting.3
Die Casting.4
Die Casting.5
Die Casting.6
Die Casting.7
Die Casting.8
Die Casting
Cutting.1
Cutting.2
Cutting.3
Cutting.4
Cutting
Grinder.1
Grinder.2
Grinder.3
Grinder.4
Grinder
Coater.1
Coater.2
Coater.3
Coater.4
Coater.5
Coater
Scheduled
Hours
--------8
8
8
8
8
8
8
8
64
8
8
8
8
32
8
8
8
8
32
8
8
8
8
8
40
Capacity
-------1
1
1
1
1
1
1
1
8
1
1
1
1
4
1
1
1
1
4
1
1
1
1
1
5
Total
Entries
------116
120
124
111
119
123
114
124
951
1422
1424
1419
1423
5688
1422
1422
1422
1422
5688
38
37
37
36
33
181
Average
Minutes
Per Entry
--------3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
0.29
0.29
0.29
0.29
0.29
0.23
0.23
0.23
0.23
0.23
11.98
12.00
12.00
12.00
11.92
11.98
Average
Contents
-------0.72
0.75
0.77
0.69
0.74
0.76
0.71
0.77
0.74
0.86
0.86
0.86
0.86
0.86
0.68
0.68
0.68
0.68
0.68
0.94
0.92
0.92
0.9
0.81
0.90
Maximum
Contents
-------1
1
1
1
1
1
1
1
8
1
1
1
1
4
1
1
1
1
4
1
1
1
1
1
5
Current
Contents
-------0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
1
2
% Util
-----72.50
75.00
77.50
69.38
74.38
76.88
71.25
77.50
74.30
86.88
86.93
86.87
86.89
86.89
68.68
68.97
68.83
68.68
68.79
94.84
92.50
92.50
90.00
81.98
90.36
IandP.1
8
IandP.2
8
IandP
16
RM storage
8
Cutting buffer
8
Grinding buffer
8
Coating buffer
8
IandPconv
8
Batch1
8
Batch2
8
Batch4
8
Scrap
8
LOCATION STATES BY PERCENTAGE
2
2808
2
2820
4
5628
500
951
999999
237
999999
237
999999
181
999999
235
72
5706
72
5688
72
5688
999999
70
(Multiple Capacity)
0.32
0.32
0.32
31.09
14.34
1.19
8.65
16.24
1.78
0.61
0.84
0.0
1.89
1.89
1.89
61.59
7.08
0.59
3.26
7.95
21.18
7.33
10.00
0
2
2
4
142
18
1
18
17
60
24
25
1
2
2
4
0
0
0
0
1
18
0
0
0
%
|
Location
Scheduled
% Partially
% |
%
Name
Hours
Empty
Occupied
Full | Down
--------------- --------- ------ --------- ----- | ---IandP.1
8
5.38
0.12 94.50 | 0.0
IandP.2
8
5.28
0.11 94.61 | 0.0
IandP
16
5.33
0.12 94.55 | 0.0
RM storage
8
20.90
79.10
0.0 | 0.0
Cutting buffer
8
13.24
86.76
0.0 | 0.0
Grinding buffer
8
40.93
59.07
0.0 | 0.0
Coating buffer
8
59.38
40.62
0.0 | 0.0
IandPconv
8
5.58
94.42
0.0 | 0.0
Batch1
8
3.64
96.36
0.0 | 0.0
Batch2
8
40.01
59.99
0.0 | 0.0
Batch4
8
17.28
82.72
0.0 | 0.0
Scrap
8 100.00
0.0
0.0 | 0.0
LOCATION STATES BY PERCENTAGE (Single Capacity/Tanks)
Location
Name
------------Die Casting.1
Die Casting.2
Die Casting.3
Die Casting.4
Die Casting.5
Die Casting.6
Die Casting.7
Die Casting.8
Die Casting
Cutting.1
Cutting.2
Cutting.3
Cutting.4
Cutting
Grinder.1
Grinder.2
Grinder.3
Grinder.4
Grinder
Coater.1
Coater.2
Coater.3
Coater.4
Coater.5
Coater
Scheduled
Hours
--------8
8
8
8
8
8
8
8
64
8
8
8
8
32
8
8
8
8
32
8
8
8
8
8
40
%
Operation
--------72.50
75.00
77.50
69.38
74.38
76.88
71.25
77.50
74.30
86.88
86.93
86.87
86.89
86.89
68.68
68.97
68.83
68.68
68.79
94.84
92.50
92.50
90.00
81.98
90.36
%
Setup
----0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
%
Idle
----17.21
18.93
18.80
18.74
16.86
18.73
19.47
19.02
18.47
13.12
13.07
13.13
13.11
13.11
31.32
31.03
31.17
31.32
31.21
5.16
7.50
7.50
10.00
18.02
9.64
%
Waiting
------0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
%
Blocked
------0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
%
Down
----10.29
6.07
3.70
11.88
8.76
4.39
9.28
3.48
7.23
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
RESOURCES
Resource
Name
------------Die to Cut
Grind to Coat
Coat to IP
Maitenance
Units
----1
1
1
1
Scheduled
Hours
--------8
8
8
8
Number
Of Times
Used
-------237
237
179
26
Average
Minutes
Per
Usage
------0.08
0.25
0.11
7.75
Average
Minutes
Travel
To Use
------0.0
0.0
0.0
0.06
Average
Minutes
Travel
To Park
------0.08
0.25
0.11
0.13
RESOURCE STATES BY PERCENTAGE
Resource
Name
Scheduled
Hours
%
In Use
%
Travel
To Use
%
Travel
To Park
%
Idle
%
Down
% Blocked
In Travel
--------0.0
0.0
0.0
0.0
% Util
-----4.64
12.47
4.33
42.36
94.56
94.66
94.61
12.32
0.0
0.0
0.0
0.0
29.43
10.19
13.90
0.0
------------- --------Die to Cut
8
Grind to Coat
8
Coat to IP
8
Maitenance
8
FAILED ARRIVALS
Entity
Location
Name
Name
------------- ---------Raw MaterialA RM storage
Raw MaterialB RM storage
Raw MaterialC RM storage
ENTITY ACTIVITY
Entity
Name
------------PlaneA
PlaneB
PlaneC
Raw MaterialA
Raw MaterialB
Raw MaterialC
Junk
ENTITY STATES
Entity
Name
------------PlaneA
PlaneB
PlaneC
Raw MaterialA
Raw MaterialB
Raw MaterialC
Junk
-----4.35
12.47
4.33
42.00
------4.05
12.47
4.33
0.36
----91.31
75.05
91.35
57.28
---0.0
0.0
0.0
0.0
Average
Minutes
In
System
------59.20
89.51
91.62
83.85
Average
Minutes
In Move
Logic
------0.65
0.37
0.37
0.46
Average
Minutes
Wait For
Res, etc.
--------18.95
17.28
17.98
18.96
Total
Failed
-----0
0
0
Current
Total
Quantity
Exits In System
----- --------1324
6
1902
66
2328
12
0
0
0
0
0
0
70
0
BY PERCENTAGE
%
In Move
Logic
------1.10
0.42
0.41
0.55
-----0.29
0.0
0.0
0.36
%
Wait For
Res, etc.
--------32.02
19.31
19.62
22.61
%
In Operation
-----------6.63
17.79
17.38
14.90
%
Blocked
------60.25
62.48
62.58
61.94
Average
Minutes
In
Operation
--------3.92
15.92
15.92
12.49
Average
Minutes
Blocked
------35.66
55.92
57.34
51.93