2.810, Nov 3, 2003 T. Gutowski & R. Salzman 1FMS System Design for Heidelberg PressT. Gutowski & R. SalzmanRefs;“Manufacturing Strategy” John Miltenburg, Productivity Press, 1995 (Ch 4)“The Design of the Factory with a Future”, J T. Black 1991 (Ch2)“Flexible Manufacturing System – Evaluation and Redesign” Salzman, Gutowski and Krebs“Manufacturing System Design: Flexible Manufacturing Systems and Value Stream Mapping” Rhonda Salzman, M.S. thesis M.E.2.810, Nov 3, 2003 T. Gutowski & R. Salzman 2OutlineIntro to Flexible Manufacturing SystemsProblem AnalysisComparisons to Other SystemsAnalysis and RedesignSimulation ResultsMaxim Cell Video2.810, Nov 3, 2003 T. Gutowski & R. Salzman 3Cincinnati MAXIM Cell(5) Machines(24) Pallets(3) Shifts2.810, Nov 3, 2003 T. Gutowski & R. Salzman 4Physical Resources3 set-up stations 4 operators per shift3 shifts2,000 active part numbers5 machines61 programs run per shift2.810, Nov 3, 2003 T. Gutowski & R. Salzman 5Typical SetupSetup with three parts on one Fixture Plate2.810, Nov 3, 2003 T. Gutowski & R. Salzman 6Progressive SetupSetup for doing two different planes on workpiece during one clamping.2.810, Nov 3, 2003 T. Gutowski & R. Salzman 7Typical Parts2.810, Nov 3, 2003 T. Gutowski & R. Salzman 8Production RateProduction Rate (PR): Number of jobs produced by the cell in a give amount of time (hourly)Orders Per Year: 1,600All calculations based on data from 1999yeardaysyearweeksweekdays250505Time Avaliable =×=daysjobsdaysjobs/4.62501600Rate Production ==hourpartshoursdayjobpartsdayjobsPR 9.5241224.6 =××=2.810, Nov 3, 2003 T. Gutowski & R. Salzman 9Work-In-ProcessWork-In-Process(WIP):Average number of jobs in the system at any given timeAssumptions: 1 job / tombstone2 tombstones / machine2 tombstones at setup stationsjobs122521WIP=+××=2.810, Nov 3, 2003 T. Gutowski & R. Salzman 10daysjobsdayjobs24.612PRWIPTime Lead ===Lead TimeLead Time (LT): Total time a part is in the system from initiation of a job to completion of the last part in its batchMaxim CellOrder Slip Picked upOrders CompletedLT2.810, Nov 3, 2003 T. Gutowski & R. Salzman 11System Summaryλ = 6.4 jobs/dayL = 12 jobsW = 2 daysTypical job size = 22 parts2 to 4 operations per partApproximately one new part each day2.810, Nov 3, 2003 T. Gutowski & R. Salzman 12Orders and Standard Hours 1999 (Cal. Year) 2001 FY 2002 FY 2003 FY 2004 FY Orders/year 1600 # of different part numbers 811 800* Standard Hours 13,334 22600 25200 39000 *estimate2.810, Nov 3, 2003 T. Gutowski & R. Salzman 13Current System NumbersUtilizationTotal ProducedParts/HourMaterial TypesNew parts/YearPart TypesProgrammersMachinistsMachines44%35,0005.98~24020005452.810, Nov 3, 2003 T. Gutowski & R. Salzman 14OutlineIntro to Flexible Manufacturing SystemsProblem AnalysisComparisons to Other SystemsAnalysis and RedesignSimulation Results2.810, Nov 3, 2003 T. Gutowski & R. Salzman 15Define the ProblemDec 1999 Study0%20%40%60%80%100%120%140%Apr-99May-99Jun-99Jul-99Aug-99Sep-99Oct-99Nov-99Dec-99Jan-00Feb-00Mar-00Apr-00May-00Jun-00Jul-00Aug-00Sep-00EFFICIENCYUTIL.YIELDUtilization: (Actual Hrs)/(Actual Hrs+NPDL)Efficiency: (Std Hrs)/(Actual Hours)Yield: Efficiency*UtilizationUtilization: (Actual Hrs)/(Actual Hrs+NPDL)Efficiency: (Std Hrs)/(Actual Hours)Yield: Efficiency*Utilization2.810, Nov 3, 2003 T. Gutowski & R. Salzman 16Data AnalysisUtilization = Spindle up time / Available timeR2 = 0.89620.00%25.00%30.00%35.00%40.00%45.00%50.00%55.00%60.00%65.00%70.00%10 15 20 25 30Avg. LotsizeUtilization2.810, Nov 3, 2003 T. Gutowski & R. Salzman 17Comparison between Utilization and Prove Out (of new CNC programs)R2 = 0.438720.00%25.00%30.00%35.00%40.00%45.00%50.00%55.00%60.00%65.00%70.00%4000 6000 8000 10000 12000 14000ProveOut Time (minutes per month)Utilization2.810, Nov 3, 2003 T. Gutowski & R. Salzman 18Elements of Utilization N-Lot SizeS-One Time Internal SetupsT-Operation TimeOF-Other FactorsOFNTSNTtilization++=U 0 1 U(N) Lot Size2.810, Nov 3, 2003 T. Gutowski & R. Salzman 19Cycle Time VariationMachine Productive Utilization: Productive Time / Event SpanSpindle Uptime Ratio: Cycle Time / Event SpanT2 TminT1 TminEvent SpanSetupTotal Cycle TimeTmin TminSetupProductive TimeTminTminNT=N(Tmin+∆T)2.810, Nov 3, 2003 T. Gutowski & R. Salzman 20Redefine UtilizationOFT)min(min+∆++=TNSNTnUtilizatioS = Set-upN = Number of PartsTmin= Minimum Processing Time∆T = “Over Cycle” Processing TimesOF = Other Factors2.810, Nov 3, 2003 T. Gutowski & R. Salzman 21Cycle Time = Spindle Up TimeProductive Time = Tmin20.00%25.00%30.00%35.00%40.00%45.00%50.00%55.00%60.00%65.00%70.00%10 15 20 25 30Average Lot SizeUtilizationProductive TimeEvent SpanCycle TimeEvent Span2.810, Nov 3, 2003 T. Gutowski & R. Salzman 220.20.30.40.50.60.70.810 12 14 16 18 20 22 24 26 28 30AVERAGE LOT SIZE PER MONTHUtilizationPT/ESNO CYCLE TIMEVARIATIONNO SETUPNO OTHER FACTORSS = 0OF = 0Productive Time / Event SpanOFT)min(min+∆++=TNSNTnUtilizatio?T=02.810, Nov 3, 2003 T. Gutowski & R. Salzman 23Machine Utilization Profile; 1997 dataSpindle up time 56%Set-up (Prove out) 9%“OF” 35%spindle up56%other 9%prove out9%no job in machine20%probe fault 8%2.810, Nov 3, 2003 T. Gutowski & R. Salzman 24No job in machineBack-up loading n internal resources (tombstones, tool, fixtures..)not availableMachine Prove-Outn New CNC program, often programming neededMachine Problemsn Maintenance neededWaiting toolsn From tool pre-setBack Up Loading39%Mach. Prove out(at other machine)34%Machine Problem13%Job at QC11%Waiting Tools3%no job in machine20%2.810, Nov 3, 2003 T. Gutowski & R. Salzman 25Spindle Down Time HistogramApproximately 30% of the available time per month the spindle is downDec 1998 Spindle Down Time Histogram01002003004005006007000:10:000:30:002:00:004:00:006:00:008:00:0010:00:0012:00:0014:00:0016:00:0018:00:0020:00:0022:00:0024:00:00FrequencyMinutesHours217565 hours2.810, Nov 3, 2003 T. Gutowski & R. Salzman 26Summary MatrixNecessary Resources for RepairReasons for Machine DownExternal InternalPre-set Engineer Program QC MaintMachinist Tombstone Tool cart MachineBackup LoadX X XMach. Prove OutX X XMachine Problem X X XJob at QCX XWaiting ToolsX X2.810, Nov 3, 2003 T. Gutowski & R. Salzman 27MAXIM 630 Cell current configuration2.810, Nov 3, 2003 T. Gutowski & R. Salzman 28OutlineIntro to Flexible Manufacturing SystemsProblem AnalysisComparisons to Other SystemsAnalysis and RedesignSimulation Results2.810, Nov 3, 2003 T. 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