Analysis of the Material Handling Requirements for Flexible

Manufacturing SystemCase Study: Line 155

Jessica Daly and Steven Tompkins

LEGO Systems, Inc.

Faculty Advisor: Dr. William Brown

Corporate Advisor: Aimee Crisanti, Senior Production Engineer

Project Overview

Problem Definition LEGO has not been able to create a method

for calculating the number of material handlers that are required to support their production schedule.

Project Objective To deliver a model for determining the

number of material handlers needed for the production of any given product on Assembly Line 155.

Solution Methodology

Determine Material Handler Functions Define the characteristics of the Line

that need to be quantified Determine variables for model Design logic equations that accurately

represent the system Calculate the baseline of the system Design a final model

Material Handler FunctionsDedicated Material

Handling Functions involve the loading of the following:

Box Erector Literature Special Counters Parts Feeders Bag Feeders Conveyors Decal Dispensers

Other Functions Product packaging

removal and clean-up Machine maintenance

System Characteristics

Capacity of Equipment Line Speed Types of Equipment Used Operation Times

Equation Variables Line Rate Type of Equipment Time for Loading Equipment P-Box Quantity Based on Weight of

Part Quantity of Parts Per Piece of

Equipment Number of Actual Material Handlers

Used

Sample Equation

Dedicated Material Handling Time Equation

(Rate of Line/Reload Amount)*(Time to Reload)*(Quantity needed in Final Assembly)

(Rate/P-Box Qty)*(.33mins)(1)=DMHT (Mins/Hr)

Baseline of System

Average Percent Dedicated Material Handling Time = Approx. 70%

Actual vs. Calculated - using 70%

0

0.5

1

1.5

2

2.5

3

3.5

1 3 5 7 9 11 13 15 17 19 21

Part

Mate

rial

Han

dle

rs

Actual

Calculated

System Modification

Literature Inserters no longer part of Assembly Line

Operators will be used in place of machines

Some loading times changed slightly

Baseline Modification Decrease in Dedicated Material Handling

Time New Total Material Handling Time

Calculated By: Other Time from Original System + New System

Dedicated Material Handling Time

New Percent DMHT: New System DMHT/ New Total Material Handling

Time = 55%

Final Model Characteristics

Microsoft Excel Model User-Friendly Adaptable to Other Assembly Lines Reprogrammable

Final Model - User Inputs

Rate of Line (pieces per hour) Quantity of Parts Weight of Specific Parts Type of Equipment Percent Dedicated Material Handling

Time

Final Model - Outputs

Total Dedicated Material Handling Time

Number of Material Handlers Needed for a Production Hour

Pie Charts Total Material Handling Time Distribution Dedicated Material Handling Time

Distribution

Distribution of Dedicated Material Handling Time

Distribution of Dedicated Material Handling Time

31%

4%

0%51%

3%

11%

Literature

SpecialCountersParts Feeders

Bag Feeders

Conveyors

Miscellaneous

Simulation of Line

Components Pieces of

Equipment Material Handlers Operators Conveyors Products

Benefits Visual Aid

What-If Analysis Line Modification

Adaptability for Other Lines

Taylor ED Model

ABET Topics of Concern

Economic Concerns and Implications Political Concerns and Implications Environment Concerns and

Implications Sustainability Social Concerns and Implications

Conclusion Objective of Project was

Accomplished Accurate Model created including

Training Manual LEGO has approved Model and is

planning implementation Schedule of Project Maintained Training at LEGO is Scheduled Additional Simulation Created

Totals Sheet of Excel ModelMaterial Handling Model    

     

Totals    

     

Literature 15.67 (mins/line hour)

Special Counters 0.00 (mins/line hour)

Parts Feeders 0.00 (mins/line hour)

Bag Feeders 20.48 (mins/line hour)

Conveyors 15.89 (mins/line hour)

Miscellaneous 2.66 (mins/line hour)

     

     

Total Time 54.709 (mins/line hour)

     

Input % Dedicated Material Handling Time 55% (use % symbol)

(Time Material Handlers are actually handling material - normal range (50-60%)    

Other Time 45%  

Number of Material Handlers needed for production 1.66  

     

Other Time (Clean Up/ Machine Jams) 44.762  

Project Schedule

Sheet 1 of Excel Model

Material Handling Model PART #3432  

  Input Column Time (mins)

     

Rate (Pcs/hour) 1680  

Box Erector   8.4

Number of Instructions 1 3.92

Number of Brochures 1 1.92

Number of Posters 0 0.98

Number of Postcards 1 0.46

     

  Total 15.67

     

Number of Decals 1 1.68

     

Other    

Number of Tables 1 0.98

Number of Boxes 0 0.00

Misc. Parts (No Equipment) 0 0.00

     

  Total 2.65944

Parts Feeders Sheet of Excel Model

Material Handling Model    

  Input Column Time(mins)

Rate 1680  

Parts Feeders    

     

Weight of 1st Element 0 0.000

Quantity 1  

Weight of 2nd Element 0 0.000

Quantity 1  

Weight of 3rd Element 0 0.000

Quantity 1  

Weight of 4th Element 0 0.000

Quantity 1  

Weight of 5th Element 0 0.000

Quantity 1  

Weight of 6th Element 0 0.000

Quantity 1  

Weight of 7th Element 0 0.000

Quantity 1  

Equations Continued

To Get Percent Dedicated Material Handling Time

((Total Dedicated Material Handling Time (Mins/Hr)/Number of Actual Material Handlers Used)*(100))/(60 Mins)

((84.25/2)*(100))/(60)= 70.21% DMHT