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Tony Ponsonby MSc Manufacturing with Management Final Project Viva Voce Business Process Simulation of a Hoist Production Line at Street Crane Ltd

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Page 1: MSc - Thesis Presentation

Tony Ponsonby MSc Manufacturing with Management

Final Project Viva Voce

Business Process Simulation of a Hoist Production Line

at Street Crane Ltd

Page 2: MSc - Thesis Presentation

Structure of Work

Model LogicData Collection

Model Building

Verification

ValidationExperimentation

Optimisation

Project Proposal

Project Definition

Project Report

Page 3: MSc - Thesis Presentation

• Purpose– Extend the life of the existing production line

• Aim– Determine how production can be increased in appropriate

stages of investment• Company / Product Characteristics

– Make-to-Order– Wide product range – Manual assembly– Cycle-times vary / out of balance– Slow throughput / Large product size

Project Definition

Page 4: MSc - Thesis Presentation

Rate x ArrivalLeadtime WIP

Time ingManufactur TotalTime AddedValue-Non Efficiency Throughput

Demand CustomerTime Available TaktTime

Time TaktTime Cycle Cell / ons Workstatiof Number

Project Key Concepts

Page 5: MSc - Thesis Presentation

Data Collection

ZX8 Frame Assembly Time - 6/8 Fall Variants

Histogram Burr

Cycle time (hrs)141210864

f(x)

0.280.260.240.22

0.20.180.160.140.12

0.10.080.060.040.02

0

Hoist Model

Qty in 2012

Iuniform from (>)

Iuniform to (<=) % Split

ZX10 60 0 60 3.77ZX6 863 60 923 54.28ZX8 667 923 1590 41.95Total 1590

Frequency Voltage CountIuniform from (>)

Iuniform to (<=) % Split Cumulative

50 380 82 0 82 2.10 2.1050 400 2963 82 3045 75.94 78.0460 230 1 3045 3046 0.03 78.0660 380 83 3046 3129 2.13 80.1960 440 1 3129 3130 0.03 80.2260 460 446 3130 3576 11.43 91.6560 575 326 3576 3902 8.35 100.00

Page 6: MSc - Thesis Presentation

Hoist Type

Cell 1Barrel Assembly

Cell 3 Frame Assembly

Cell 4 Trolley

Assembly 1&2

Cell 6 Cable Routing

Cell 7 Load Test& Rope Up

Cell 8 CRB / FMAssembly

Cell 9 End-of-Line

Test

Cell 10 Packing

Cell 11.1Mechanical Assembly

Cell 11.3 Cable Route &Test

Hoist Type

All ZX10 HoistsAll ZX10 Hoists

All ZX8 HoistsAll ZX8 Hoists

ZX86 , 88 OR 10ZX86 , 88 OR 10

Hoist TypeAny 2or4 Fall CRB Hoist

Any 2or4 Fall CRB Hoist

LHR & FMHoistsLHR & FMHoists

Any 2 or 4 FallZX6 or 8 LHR

Hoist Model

Any 2 or 4 FallZX6 or 8 LHR

Hoist Model

Cell 11.4Crab

Assembly

OutOut

Any 2 or 4 FallZX6/8 FM / CRB Hoist Model

Any 2 or 4 FallZX6/8 FM / CRB Hoist Model

Cell 8 Fit Crab Frame to Hoist

Any 6or8Fall CRB Hoist

Any 6or8Fall CRB Hoist

Order In

In If Hoistis a ZX8Model

In If Hoistis a ZX8Model

BuildFrameFrom Store

InIn

BuildFrameFrom Store

OutOut BuildFrameTo Store

Despatch Hoist

InIn

Generator usedif hoist is a Non-UK

mains supply

Generator usedif hoist is a Non-UK

mains supply

Model Logic

Page 7: MSc - Thesis Presentation

• Hoist type – Size– Build time– Routing

• Labour / Shift Pattern

• Resource Requirement– Workstations– Generator– Build-frames

• Entity feeding

• Buffer size

• Simulation Data Input

• Key Performance Indicators– Throughput Efficiency– Quantity Dispatched– Lead-time– WIP

Model Building Considerations

Page 8: MSc - Thesis Presentation

Warm-Up Period

73.5 - Avg72.1 - Min

74.9 - Max

0

10

20

30

40

50

60

70

80

90

0

168

336

504

672

840

1008

1176

1344

1512

1680

1848

2016

2184

2352

2520

2688

2856

3024

3192

3360

3528

3696

3864

4032

4200

4368

4536

4704

4872

Labo

ur U

tilisa

tion

%

Time (Hours)

Warm-Up Period (Without Starting Conditions)

Labour Utilisation

Average Labour Utilisation

Minimum Labour Utilisation

Maximum Labour Utilisation

Transient Steady State

75.1 - Avg72.5 - Min

78.85 - Max

0

10

20

30

40

50

60

70

80

90

0

168

336

504

672

840

1008

1176

1344

1512

1680

1848

2016

2184

2352

2520

2688

2856

3024

3192

3360

3528

3696

3864

4032

4200

4368

4536

4704

4872

Labo

ur U

tilisa

tion

%

Time (Hours)

Warm-Up Period (With Starting Conditions)

Labour Utilisation

Average Labour Utilisation

Minimum Labour Utilisation

Maximum Labour Utilisation

Transient Steady State

Model Building Considerations

Page 9: MSc - Thesis Presentation

Model Building & Verification

Page 10: MSc - Thesis Presentation

Validation

Model HistoricalZX6 CRB 2 TO 4 14.52 14.66 -0.94%ZX6 FM 2 TO 4 11.81 11.98 -1.34%ZX6 LHR 2 TO 4 13.76 13.91 -1.05%ZX8 CRB 2 TO 4 23.29 23.44 -0.66%ZX8 FM 2 TO 4 19.78 20.24 -2.27%ZX8 LHR 2 TO 4 19.63 19.99 -1.81%ZX8 CRB 6 TO 8 35.91 35.00 2.59%ZX8 FM 6 TO 8 29.87 30.09 -0.72%ZX8 LHR 6 TO 8 35.99 35.24 2.12%

ZX10 DD ALL 42.93 41.77 2.79%ZX10 ST OR SS ALL 32.05 31.93 0.40%

Hoist Model

Average Processing Time (hrs)

Error %

Hoist Type

Number of Falls

Part 1 – Comparison of actual to simulated average production hours

Page 11: MSc - Thesis Presentation

Validation

Model

Number of Hoists Produced

Product Split (%)

Average Number of Hoists Produced

Product Split (%)

ZX10 60 3.77% 47.56 2.98%ZX6 863 54.28% 885.4 55.52%ZX8 667 41.95% 661.72 41.49%Total 1590 1594.78

Validation Model2012 Hoist Production

Model

Actual Average Throughput Efficiency in

2012 (%)

Simulation Average

Throughput Efficiency (%)

% Error From Actual

ZX10 6.4 6.222 -2.8408%ZX6 5.1 5.004 -2.0135%ZX8 5.5 5.269 -4.7702%

2012 Actual Simulation Difference Error (%)Labour Hours Recorded 26113.6 29001.261 2887.6 11.06%Calculated Time Not Recorded 3013.2 - - -Total Labour Hours 29126.8 29001.261 -125.6 -0.43%

Product Split

Throughput Efficiency

Total Production Hours

Validation 2 – Comparison of 2012 KPI’s to simulation

Page 12: MSc - Thesis Presentation

Capacity of Existing System

2nd Optimisation

Capacity of 1st optimised system without capital

investment

Capacity of 1st optimised system

with capital investment

1 - Determine the maximum capacity at current and theoretical TE

1st Optimisation Without capital

investment

Capacity of 2nd optimised system

Experimentation & Optimisation

Page 13: MSc - Thesis Presentation

3.0

3.5

4.0

4.5

5.0

5.5

6.0

6.5

7.0

7.5

8.0

1500

1750

2000

2250

2500

2750

3000

3250

3500

3750

4000

Existing System

Exp 1 -Max

Output

Exp 1 -Max

Output

Exp 2 - 1st Opt Conf

Exp 2 - 1st Opt Conf

Exp 3 -Investment

Exp 3 -Investment

Exp 4 - 2nd Opt Conf

Delayed Delayed No Delay Delayed No Delay Delayed No Delay No Delay

Hoi

sts D

ispa

tche

d / m

²

Hoi

sts D

ispa

tche

d / Y

ear

ExperimentScenario

Experiment Comparison (Dispatch Quantity Vs Space Utilisation)QTY Dispatched

Hoists / m² of building

50.0

55.0

60.0

65.0

70.0

75.0

80.0

85.0

90.0

95.0

100.0

6

7

8

9

10

11

12

13

14

15

16

Existing System

Exp 1 -Max

Output

Exp 1 -Max

Output

Exp 2 -1st Opt Conf

Exp 2 -1st Opt Conf

Exp 3 -Investment

Exp 3 -Investment

Exp 4 -2nd Opt Conf

Delayed Delayed No Delay Delayed No Delay Delayed No Delay No Delay

WIP

Lead-

Tim

e (D

ays)

ExperimentScenario

Experiment Comparison (Lead-time Vs WIP)Lead-Time (days)

WIP Quantity

Experimentation & Optimisation

Existing System Delay

Existing System

No Delay

Optimised System No

Delay

Optimised System Delay

Optimised System Delay +

Investment

Optimised System No

Delay + Investment

2nd Optimised

systemNumber of Hoists Shipped / Year 1718 1801.8 1978.8 1915.4 2293 3425 3890.2Date Oct-2013 Apr-2014 Dec-2014 Mar-2015 Oct-2016 Feb-2021 May-2022

1 - Determine the maximum capacity at current and theoretical TE

Page 14: MSc - Thesis Presentation

20122013

20142015

2016

2017

2019

2020

2021

2022

0

250

500

750

1000

1250

1500

1750

2000

2250

2500

2750

3000

3250

3500

3750

4000

0% 10% 20% 30% 40% 50% 60% 70%

Num

ber o

f Hoi

sts

Ship

ped

% Generator Requirement

Output vs Generator Requirement

Future Generator Requirement8 Generators

7 Generators

6 Generators

5 Generators

4 Generators

3 Generators

2 Generators

1 Generator

Experimentation & Optimisation2 - Determine the number of generators to sustain production

Page 15: MSc - Thesis Presentation

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

0.5

0

50

100

150

200

250

300

350

400

450

500

4% 5% 6% 7% 8% 9% 10% 11% 12%

Hoist

s / h

r

WIP

Qua

ntity

Ho

urs

Avg Throughput Efficiency (%)

Effect of Throughput Efficiency on Littles Law Avg Wip

Avg Leadtime (hrs)

Avg Wasted Time (hrs)

Arrival Rate (Hoists/hr)

Experimentation & Optimisation3 - Determine the maximum capacity of an externally constrained system

Page 16: MSc - Thesis Presentation

Questions

Page 17: MSc - Thesis Presentation

86

27 2213 10 7 6

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0

10

20

30

40

50

60

70

80

90

100

Wai

ting

in

Que

ues

Wai

ting

for I

n-

Hous

e Pa

rts

Inco

rrec

t Pl

anni

ng

Wai

ting

for

Boug

ht-In

Part

s

Wai

ting

for

Peop

le

Wai

ting

for

Equi

pmen

t

Wai

ting

for

Info

rmati

on

Num

ber o

f D

elay

s O

bser

ved

Delay Category

Instances of Delay

Delay Occurances

Cummulative Percentage