capstone project iee545 cjg
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8/11/2019 Capstone Project IEE545 CJG
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Team CJG
Capstone
ProjectI E E 5 4 5 - D r. To r r e s -G a r c i a
SM ELECTRONICSCOST SAVINGS THROUGH SIMULATION
ANALYSIS
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Chris WeinkaufQuality Systems Plant ManagerB.S. 2012 Chemical EngineeringContact: cweinkau@asu.edu
J ohnathon WrightApplications EngineerB.S. 2012 Mechanical EngineeringContact: jswrigh2@asu.edu
* G abriel SilvaSr. Software EngineerB.S. 2004 Computer ScienceContact: glsilva@asu.edu
PROJECT TEAM
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Project Introduction GabrielProblemProject PurposeAssumptions
Model ChrisKey PartsDesignInteractive video
Results/Conclusions JohnathonResultsRecommendationsSuggested future research
OUTLINE
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ProblemFactory:
Key Issues:Single input conveyor with maximum capacity of 40 partsSingle input conveyor accepts random part typesFourth line requires significant setup/process/jam time
PROJECT INTRODUCTION
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Project Purpose?Determine cost of lines A,B, and C shutting down
Analyze design and efficiency of theSingle input conveyorFourth and final line (cells 1-8)
Analyze alternatives to improve cost reductionAdd more pallets
$17K + $3K for each new palletBenefit: More parts to work in the fourth line
Add 3 additional buffer conveyors
$56KBenefit:
Additional space to store partsBatches of parts fed into fourth line reducing required setup time
Can consider both alternatives
PROJECT INTRODUCTION
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AssumptionsNegligible transfer time from input conveyor to line 4Cell 8 will first take a new part even if cell 7 is ready to transfer to itLimitation on the number pallets is 48
Two year ROI to consider an alternative
PROJECT INTRODUCTION
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Key PartsFour different models required for comparison
1. Current Process (no modifications)2. Extra Pallets
3. Buffer Lines for Parts A, B, and C4. Buffer Lines and Extra Pallets
Modules Types within the ModelPart Entry into the Holding ConveyorAutomatic CellsManual CellsCell 8Completed Part ExitLost Part Exit
ARENA MODEL
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DesignCommon Modules
Cell 8Automatic Cells
Manual CellsCompleted Part ExitLost Part Exit
ARENA MODEL
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Model DifferencesExtra Pallets do not change the model logic
Only difference is more pallets are available
Main difference between Normal Process and Buffer Lines Models is
the Entry Module
ARENA MODEL
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ARENA MODEL
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M1 is the model of current systemM2 is the model of adding additional pallets (resources).M3 is the model of adding buffer lines ($56k investment).M4 is the model of the production line with buffer lines andadditional pallets combined (M2+M3).
Objective: Maximize Profit.Comparing M1M2
Comparing M1M3
Comparing M1M4
RESULTS
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RecommendationsBuffer Lines Meet 2YR ROI criteria and should be implemented.
$56K initial cost, approximately $75,000 (+25k) return after 2 years.
Additional pallets showed no effect on results and should NOT be
implemented ($17K initial investment, plus $3K per pallet).Suggested Future Research
Consider upgrading tools with faster loading and processing times.Analyze the buffer line system to find batch sizes that maximizeproduction.
Consider making individual production lines for each par t, or movingto a larger production facility to maximize profits.
CONCLUSION
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