MICHIGAN MANUFACTURING TECHNOLOGY CENTERMMTC is an affiliate of the NIST Manufacturing Extension Partnership (MEP) and supported by the Michigan Economic Development Corporation (MEDC).

Utilizing Simulation in Lean Six Sigma

April 9th, 2014

MICHIGAN MANUFACTURING TECHNOLOGY CENTER

Steve Napier

©2014 MMTC

Over 20 years of software and hardware-in-the-loop simulation Full motion flight simulator Automotive vehicle testing Hardware/software product development

Current Applications – Lean Six Sigma consulting, Process Improvement

BS/MS Engineering

Plymouth, Michigan

MICHIGAN MANUFACTURING TECHNOLOGY CENTER

Michigan Manufacturing Technology Center (MMTC) Plymouth, MI

Since 1991, MMTC has assisted Michigan’s small and medium-sized businesses compete and grow.

Serve more than 500+ companies annually 30+ employees and 10+ practitioners Directly assist industry clients with growth, continuous

improvement, and compliance Supported by the Michigan Economic Development Corporation as

Michigan's National Institute of Standards and Technology Manufacturing Extension Partnership (MEP) affiliate, we bring well-tested services to our MEP clients.

© 2014 MMTC 2

MICHIGAN MANUFACTURING TECHNOLOGY CENTERVisualizing the Effect of Change

© 2014 MMTC

The Lean Six Sigma service line helps clients improve operations by reducing waste and defects

Sometimes we provide specific ideas that would be beneficial, but the client can’t let go of the status quo

Simulation gives us the opportunity to demonstrate the process changes

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MICHIGAN MANUFACTURING TECHNOLOGY CENTER

Scenario – Loading a Paint Line

A continuous paint line with a very complex mix of parts Approx. 100 unique parts, up to 142 racks per day 80 sec cycle time, 581 racks per day, high & low bake

temperatures Time to load racks - Min: 30 sec Max: 6 min Weighted Ave:

2.6 min Time to unload - Min: 1.7 min Max: 19.3 min Weighted Ave:

9.2 min

© 2014 MMTC 4

MICHIGAN MANUFACTURING TECHNOLOGY CENTER

Starting Point

©2014 MMTC

MICHIGAN MANUFACTURING TECHNOLOGY CENTER

SIMUL8 Software Model Demo

Demonstrated the process complexity using a simple model of the load, paint and unload

The model confirmed the number of stations and employees needed to maintain an 80 sec cycle time

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Alternate Configuration

MMTC

• Developed using cues from the existing AutoCAD® models• Incorporates material handling racks for the containers• Frames or racks are populated in lanes and loaded onto the conveyor

7Incoming Material Handling Lane Office

2040 sq. ft.

Lane for Unpainted Carts Office

1104 sq. ft.

Material Handling LaneOffice

1578 sq. ft.

Material Handling/Pedistrian

Lane

Office

1458 sq. ft.

Material Handling/Pedistrian

Lane

Office

1092 sq. ft.

Lane for Painted Carts Office

1104 sq. ft.

Unpainted Material Container Flow Racks

Empty Container Flow Racks

Painted Material Container Flow Racks

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Pa

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Sequence Coordinator

Finished Goods

Person 1

Warehouse

Warehouse

5 Day WIP Storage140 ft x 16 ft 4 high 4 deep

Office

2240 sq. ft.

WIP Material Handling Lane Office

1680 sq. ft.

Warehouse

Rack Storage Office

1000 sq. ft.

Final Audit

Office

605 sq. ft.

FinesseOffice

242 sq. ft.

Painted Material Handling LaneOffice

1680 sq. ft.

Office

120 sq. ft.