Jai Hind Cycle Inc'

1
Jai Hind Cycle Inc.

• Presented By
• Mike Seide
• Sean McCauley
• Matt Zbylut
• Rebecca Gramse

2
Outline

• Introduction
• Assumptions
• As-Is Model
• Deterministic Model
• FMS
• To-Be Model
• Results / Recommendation

3
Introduction

• Jai Hind Cycles produces bicycles and is planning
  on introducing a new model of mountain bike
  strictly for the export market
• The company currently runs one shift per day and
  is considering replacing their existing factory
  layout with a cellular, group technology layout

4
Assumptions

• Production at 82,000 units would be interpreted
  as 328 bikes per production day
• Of those 328 bikes, 200 would be regular bikes
  and 128 would be mountain bikes
• 250 work days/year 2080 work hours/year 8 hour
  work days
• Anything not produced is sub-contracted or
  purchased from the market for the final assembly
• A 100 hour warm-up period was used to reach
  steady state

5
As-Is Model

• Job shop facility layout
• Current Production of 200 regular bikes per day
• High quantity of casting and final assembly
  machines
• Inefficient workspace

6
Building the As-Is Model
7
Deterministic Model Bottleneck Model

• Bottleneck model is used to provide starting
  estimates of the FMS design parameters
• Performed the bottleneck model assuming that 333
  bikes will be leaving the system

8
FMS Used in Model

• Cellular Manufacturing Layout
• Use of simple machines, no custom jigs
• Use of AGVS for transportation
• Cross Trained Workforce

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To-Be Model Assumptions

• AGVS speed is set to a maximum of 5 mph
• Human workers will transport the goods between
  cells
• Human worker speed empty is 300 fpm and full is
  250 fpm
• The operators and AGVS will return home when idle
• Production runs two 8 hour shifts per day
• AGVSs are used to transport raw materials from
  Raw Material Receiving/Storage to the designated
  queues.
• Each cell contains 1 machine of each type

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To-Be Model

• Incorporated Group Technology with Cellular
  Manufacturing
• Part Families, like characteristics
• AGVS
• Delivering raw materials to cells
• Workers
• Path network, constantly moving to different
  cells for assistance or assembly

11
Building the To-Be Model
12
To-Be Model Results

• Bottlenecks
• Frame cell and Handle Bar cell was over utilized
• Reduced by adding cells to both
• Production increased to 333 bikes per day
• Reduced labor by adding AGVS delivery system of
  raw materials
• Reduced of workers by incorporating floating
  worker design

13
Recommendations

• Implement the Group Technology Cellular
  Manufacturing layout
• Add capacity to the frame and handle bar cells
• Use AGVS to reduce workers and increase
  efficiency
• Use workers to transport materials between cells

14
Questions??