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Airplane Section - 54053

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Transcript of Airplane Section - 54053

Model the airplane manufacturing facility
Adapt model characteristics in order to achieve given goals:
Reduce cycle time to 3.5 days
Manufacture a total of 100 airplanes following the probability distribution
At the same time, optimize the number of workers required in order to reduce costs

Aerospace Manufacturing Problem
SIMIO Student Competition

1. Model Assumptions
2. Design and modeling
3. Key Performance Indicators Used
4. Verification and Validation
5. Animation
6. Experimentation of alternatives
7. Answers to challenges
8. Recommendations

Presentation Agenda
Airplane arrivals happen every 4 calendar days
Additional workers:
They are outsourced and can only work shifts 1 and 2 in weekdays
They have a 90% learning curve which can be modelled with Wright’s model
They achieve 100% effectiveness after 10 airplanes have passed through the station. This is because they are taught the process by regular workers
Processing time is calculated with a weighted average
Initially, wings arrive during weekdays and one pair at a time
The simulation run starts at 6:00 am on Monday ends after 100 airplanes have been produced

Model Assumptions
5 work stations modeled as servers except station 3, which is modeled as a combiner
There are 3 different types of airplanes, represented as one model entity with three types
Every group of 8 workers is assigned to one station only and are modeled as resources.
There are two servers, one produces airplanes and the second one creates pairs of wings
Scenarios are activated through referenced properties

Design and modeling
Airplane time between exits
Objective is to reduce it to 3.5 days
Additional workers hired
Worker shifts
Minimize worker on-shift time

Key Performance Indicators Used
1. Designed basic model
1 production line
No extra workers
Airplane types

2. Viewed system animation and output information to verify system characteristics (airplanes moving every 4 days and crane being seized only for first 6 activities) and assumptions worked properly

3. Made appropriate corrections until all conditions were met

Verification and Validation
Basic model, 3 plane type added, comparison between one and two production lines, 1 wing set at a time

Experimentation of alternatives
Basic model, 3 plane type added, comparison between one and two production lines, 2 wing sets at a time

Experimentation of alternatives
No travelled work
Introduction of additional workers
As shown before, a second production line is recommended if production time is to be reduced from 4 to 3.5 days

The use of the third shift was avoided as we assumed it was expensive and we found we could achieve the required results through different means. The number of additional workers was minimized.

Answers to challenges
Two optimal situations were found in order to reduce the cycle time from 4 to 3.5 days.
Shifts 1 and 2 with weekend (close to 3.5 days per plane, under objective)

Answers to challenges
Shifts 1, 2, and 3 without weekend (over objective)

Answers to challenges
Install second production line

Negotiate wing set arrivals with supplier to increase from 1 wing set to 2

Hire no additional workers as their contribution to reducing time is not significant

Cost-analysis between using Shifts 1 and 2 throughout the week or Shifts 1, 2 and 3 in weekdays

Full transcript