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CASESTUDY1THEPRODUCTIONLINEINCONTROLENTERPRISEDYNAMICS11CASESTUDY1THEPRODUCTIONLINE11INTRODUCTIONINFLOWLINEPRODUCTION,THEPRODUCTIONEQUIPMENTISLAIDOUTINTHEPRODUCTIONSEQUENCETHEPRODUCTSUSUALLYFOLLOWTHESAMEROUTETHROUGHTHESYSTEMTHISTYPEOFSYSTEMISFREQUENTLYVERYSENSITIVETOEQUIPMENTBREAKDOWNS,BECAUSEIFONEPROCESSSTOPS,THISSTOPSTHEENTIRELINEHAVINGSTOCKBETWEENEACHPROCESSCANREDUCETHISSENSITIVITYFLOWLINESYSTEMSAREMOSTUSEFULFORMEDIUMTOLONGPRODUCTIONRUNS12DESCRIPTIONOFTHESITUATIONAFACTORYPRODUCINGARANGEOFVEHICLESISCONSIDERINGADDINGANEWHIGHQUALITYTRAILERTOTHERANGEBECAUSEACOMPETITORHASCEASEDTOTRADE,ITISBELIEVEDTHATSUBSTANTIALSALESCANBEEXPECTEDOVERTHECOMINGYEARSTOMEETTHISANTICIPATEDDEMAND,ANEWASSEMBLYLINEISPLANNEDWHICHWILLBEEQUIPPEDMAINLYWITHROBOTSTHETRAILERASSEMBLYCANBEDIVIDEDINTOFIVEMAINOPERATIONSASINGLEROBOTCARRIESOUTEACHOPERATIONATTHEFIRSTOPERATIONA,THEAXLESANDWHEELSAREFITTEDTOTHEFRAMETHISISFOLLOWEDBYMOUNTINGTHEUNDERSIDEONTOTHEFRAMEBTHEVEHICLESIDESARETHENATTACHEDCFOLLOWEDBYTHEROOFDTHEFINALASSEMBLYOPERATIONANDQUALITYCHECKEISNOTAUTOMATED,ASCUSTOMERSOFTENHAVESPECIALREQUIREMENTSSEEFIGURE11FIGURE11THEPRODUCTIONLINEALLTHEPARTSUSEDFORTHEASSEMBLYARESTANDARDTHEREARESEVERALTYPESOFSOMEPARTS,BUTTHESEHAVENOEFFECTONTHEPROCESSINGSPEEDALSO,THEREISALWAYSANADEQUATESTOCKOFPARTSTOSUPPLYTHELINEALTHOUGHTHEFIRSTFOURPROCESSESAREFULLYAUTOMATED,ITHASNOTBEENPOSSIBLETOSYNCHRONIZETHEMPRECISELYAXLETOFRAMEASSEMBLYATAKESANAVERAGEOF15MINUTES,ASDOESATTACHINGTHEUNDERSIDETOTHEFRAMEBASSEMBLINGTHESIDESTOTHEFRAMECREQUIRESANAVERAGEOF18MINUTES,ANDTHEROOFASSEMBLYDISAPRECISIONPROCESSANDONLYTHREETRAILERSPERHOURCANBECOMPLETEDFINALASSEMBLYANDQUALITYCHECKEISAMANUALOPERATIONANDTAKEANAVERAGEOF18MINUTESASMENTIONEDABOVE,THEACTUALPARTSUSEDATEACHSTAGEDOESNOTAFFECTTHEPROCESSESTHEFIRSTFOURPROCESSESFOLLOWAUNIFORMDISTRIBUTIONWITHARANGEOF2MINUTES,SOA15MINUTEPROCESSIMPLIESARANGEFROM14TO16MINUTESTHEPROCESSINGTIMEFORTHEFINALOPERATIONFOLLOWSANORMALDISTRIBUTIONWITHASTANDARDDEVIATIONOF3MINUTESINTHEFACTORY,THEWORKINGDAYCONSISTSOF8HOURSAND5WORKINGDAYSFORMONEWORKINGWEEKPRODUCTIONSTARTSEVERYWORKINGDAYWHERETHEDAYBEFOREHASENDEDTHEROBOTSARENOTCOMPLETELYTROUBLEFREETHEROBOTSSUPPLIERGUARANTEESTHATTHEROBOTSWILLGETFAILURESONLYONCEANHOURNEGATIVEEXPONENTIALLYDISTRIBUTEDANDINCLUDINGREPAIRTIMEINTERNALCHECKSHAVEKEPTTHEAVERAGEREPAIRTIMEWITHINREASONABLEBOUNDS,ANDASARESULTTHISTIMESEEMSTOBEEXPONENTIALLYDISTRIBUTEDWITHANAVERAGEOF6MINUTESAAXLEANDWHEELSBBOTTOMCSIDESDROOFEFINALASSEMBLYCASESTUDY1THEPRODUCTIONLINEINCONTROLENTERPRISEDYNAMICS2THESPACEAVAILABLEFORTHEPRODUCTIONLINEISVERYLIMITED,ANDASARESULTTHELINECANACCOMMODATEONLYFIVETRAILERSTHISMEANSTHATTHEREISNOROOMFORANYBUFFERZONESBETWEENTHESTEPSOFTHEPROCESSASEACHTRAILERISFINISHED,ITISMOVEDTOTHESTORAGEYARDTHEMANAGEMENTNOWWISHTOCONCLUDECONTRACTNEGOTIATIONSWITHPOTENTIALBUYERS,LEADINGTOLONGTERMCOMMITMENTSFORQUANTITIESTOBESUPPLIEDHOWEVER,THECAPACITYFORTHENEWLINEISUNKNOWN,ANDAREALISTICESTIMATEOFTHISONAWEEKLYBASISISREQUIRED13ASSIGNMENTS1ONTHEBASISOFTHECASESTUDYINFORMATION,TRYTOMAKEANESTIMATEFORTHECAPACITYPERWEEK,ANDEXPLAINHOWYOUREACHTHISCONCLUSION2CREATEASIMULATIONMODELTODETERMINETHEWEEKLYPRODUCTIONANDMAKEANEXPERIMENTWITHAWARMUPPERIODOFONEWEEKANDAMEASUREMENTPERIODOF10WEEKSDOYOURRESULTSCORRESPONDTOYOURESTIMATIONWHATISTHECAUSEOFPOSSIBLEDIFFERENCESFLOWSHOP1MOD3THEMANAGEMENTWANTSTOCOMPARETHEFOLLOWINGTWOSTRATEGIESSTRATEGY1REDUCTIONOFTHEAVERAGEREPAIRTIMEOFTHEROBOTSTO3MINUTESFLOWSHOP2MODSTRATEGY2EXTENSIONOFTHEASSEMBLYLINEBYADDING2BUFFERZONES,EACHWITHENOUGHSPACEFORONETRAILERFLOWSHOP3MODNBSEVERALCHOICESAREPOSSIBLETRYTOMAKETHERIGHTCHOICEACCORDINGTOLOGISTICSPRINCIPLESCASESTUDY1THEPRODUCTIONLINEINCONTROLENTERPRISEDYNAMICS32SUGGESTIONSFORMODELLINGINEDTHEMODELSCANEASILYBECREATEDINENTERPRISEDYNAMICSWEADVISEYOUTOALWAYSUSETHESTANDARDATOMSFORMODELLINGTHEROBOTSANDWORKERDONOTNEEDTOBEMODELLEDSEPARATELYWHYEXPERIMENTSAREDESIGNEDBYUSINGTHEEXPERIMENTWIZARDINTHEEXPERIMENTATIONMENUFORANEXPLENATIONOFTHE“EXPERIMENTWIZARD”CHECKTHETUTORIALSSECTIONOFTHEHELPMENUTHEROBOTSFAILURERATEANDREPAIRTIMESCANBEMODELLEDWITHTHESTANDARDSERVERATOMTHISATOMENABLESYOUTODEFINETHEAVERAGETIMEBETWEENFAILURESMTBFASWELLASTHEDURATIONOFTHEREPAIRMTTRFORMOREDETAILS,PLEASEREADANNEX2OFTHETUTORIALCASESTUDY1THEPRODUCTIONLINEINCONTROLENTERPRISEDYNAMICS43WORKEDEXAMPLESTHEPRODUCTIONLINETEACHERSNOTETHISCASESTUDYISANEXCELLENTEXERCISETOCONCLUDEANINITIALINTRODUCTIONTOEDSTUDENTSAREREQUIREDTOMAKETHEIROWNESTIMATEOFTHEWEEKLYCAPACITYANDTESTTHISBYBUILDINGAMODELINMOSTCASESTHEIRESTIMATESWILLTURNOUTTOBETOOHIGHBECAUSETHEEFFECTOFLINEBLOCKINGISNOTTAKENINTOACCOUNTTHECOUPLINGOFTHEADVANTAGESANDDRAWBACKSOFLINEPRODUCTIONANDGOLDRATTSIDEASONBOTTLENECKSAREOBVIOUSITISALSOANILLUSTRATIONOFHOWEVENASIMPLEPROBLEMCANBEDIFFICULTTOANALYSE,ANDSUPPORTSTHENEEDFORSIMULATIONASANINVESTIGATIONMETHOD31ASSIGNMENT1THEBOTTLENECKINTHEPRODUCTIONLINESTEPSISD,WHEREANAVERAGEOF3TRAILERSPERHOURAREEQUIPPEDWITHAROOFASARESULT,TRAILERSCANTHEORETICALLYLEAVETHEFACTORY120583EVERYWEEKHOWEVER,THELOSSOF10OFPRODUCTIONTIMEDUETOROBOTFAILUREHASTOBEALLOWEDFORCONSEQUENTLY,THEAVERAGEPRODUCTIONSEEMSTORESULTIN12012108TRAILERSPERWEEKTHEEFFECTOFBLOCKINGISNOTCONSIDEREDINTHISCALCULATIONBLOCKINGOCCURSWHENAPROCESSISCOMPLETED,BUTTHEPRODUCTCANNOTPROCEEDTOTHENEXTOPERATIONBECAUSETHATISSTILLBUSY,ORISUNDERREPAIRTHISEFFECTISHARDTOCALCULATEANALYTICALLY32ASSIGNMENTS22STRATEGY1WITHASHORTERFAILUREDURATION3STRATEGY2WITHTWOBUFFERZONESABUFFERISTHEMOSTEFFECTIVEWHENITENABLESTHEBOTTLENECKTOFUNCTIONOPTIMALLYTHEREFORE,THEBUFFERSAREPLACEDPRIORTOANDBEHINDPRODUCTIONSTEPDCASESTUDY1THEPRODUCTIONLINEINCONTROLENTERPRISEDYNAMICS6324ANALYSISOFTHERESULTSTHERESULTSOFTHEVARIOUSEXPERIMENTSAREDISPLAYEDINTHEBELOWTABLEBECAUSEOFTHESTOCHASTICDISTRIBUTIONS,THERESULTSYOUHAVEMEASUREDMIGHTSOMEWHATDIFFERFROMTHOSEMENTIONEDINTHETABLEINBROADOUTLINE,THERESULTSSHOULDHOWEVERBEEQUALSCENARIOWEEKPRODUCTIONSTANDARD957REDUCEDREPAIRTIME1088BUFFERBEFOREANDAFTERD1037325CONCLUSIONANDRECOMMENDATIONSTHEWEEKPRODUCTIONOF108TRAILERSCALCULATEDBEFOREHANDISTOTALLYUNFEASIBLEINTHEFIRSTSCENARIO,ANUMBEROF95TRAILERSAWEEKAPPEARSACHIEVABLETHEEFFECTOFTHEREDUCTIONOFTHEREPAIRTIMETURNSOUTTOBESUBSTANTIAL12TRAILERSAWEEKEXTRAONTHEAVERAGEABUFFERPRIORTOANDBEHINDSTEPDALSOHASAPOSITIVEEFFECTASUPPLEMENTOF8TRAILERSPERWEEKONTHEAVERAGEWEHAVEPUTABUFFERBEFOREANDAFTERD,BUTTHEREARE6POSSIBILITIESFORPLACINGBUFFERSASIMULATIONWITHABUFFERPRIORTOANDBEHINDCGIVESABETTEROUTCOMETEACHERSNOTEYOUMIGHTLIKETOTRYANADDITIONALEXERCISETOSTUDYTHEEFFECTOFACHAINOFPROCESSESTAKETHEMODELOFTHEORIGINALPROCESS,BUTSETTHEPROCESSTIMESOFALLPROCESSSTEPSONNEGEXP36,THEMTTFONNEGEXP3600ANDTHEMTTRONNEGEXP900WENOWHAVEALINEWITHFIVEIDENTICALPROCESSSTEPS,WHICHHAVEINPRINCIPLEACAPACITYOF100PRODUCTSPERHOUR,BUTWHEREFAILURESARETAKINGPLACEAQUARTEROFTHETIMEHOWHIGHDOESTHEAVERAGEHOURPRODUCTIONGETANDWHICHUTILIZATIONISTOBEEXPECTEDANALYTICALLY,075523WOULDBEAPRETTYGOODSUGGESTIONFORTHEUTILIZATIONTHUS23PRODUCTSPERHOURWHYTESTTHISIDEATESTTHEIDEAONCEAGAINBYREPLACINGNEGEXP36BY36CONSTANTEXPLAINTHEOUTCOMEANDTHEDIFFERENCESCASESTUDY1THEPRODUCTIONLINEINCONTROLENTERPRISEDYNAMICS74EXPLANATIONOFTHEMODELINTHISCHAPTER,WEWILLSTUDYTHEMODELMORETHOROUGHLYBYPOINTINGOUTTHEPROBLEMSOCCURRINGINTHECASESTUDYASWELLASHOWTHEYHAVEBEENSOLVEDINTHEWORKEDSOLUTION41THESTANDARDMODELTHESTANDARDMODELISTHEMODELASPRESENTEDINTHEASSIGNMENTDEFINITIONWHENMODELLINGTHISMODELINENTERPRISEDYNA
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