Labor Planning for a Manufacturing Line TEK Team Lane Ballard Christine Cheung Justin Ging Omur Kaya David Jackson Alyson NaughtonAgenda • Introduction • Formulation of LP Model • Use and Demonstration of LP Model • LP Model LimitationsTI Precision Thermostat Styles (Images of six Klixon Precision Thermostats)Weld connector Vacuum bake and tig weld Laser weldCalibrate (3) Disc Sort pins Weld arm to header Weld contact to header Weld contact to arm Wire land write up QC (2) Creep test (3) Temp check (5) Leak check 40% 60% Tin dip terminals 40% 10% 15% 75% 10% 25% 25% Clean room 100K Clean room 100 ( ) indicate # of workstations greater than 1 Factory Flow assemble eads (2) Inspection Hypot test Code BendLine History & Need For Model Higher paid, high experience workers Line History • Line in existence since 1960’s • Wide range of skill leads to complex staffing pay (pay code, shift differential, clean room pay) • Some operators employed on line since 1960’s!! Consequently current work force is well cross trained but‘top heavy’ and may not be ideal Base pay, low experience workers Current Need Model Addresses • Opportunities exist to manage and minimize labor cost on the production line given varying demandDescription of the LP Model Decision Variables Work Hours For Each Pay Code and Operation # of Shifts 1st Shift Operation 1.1 2.1 3.1 4.1 5.1 Sort Pins 7.73 0.00 0.00 0.00 0.00 Weld contact to Header 0.00 8.00 0.00 0.00 0.00 Weld contact to Arm 0.00 8.00 0.00 0.00 0.00 Weld Arm to Header 0.00 8.00 0.00 0.00 0.00 Disc Assemble 5.37 0.00 0.00 0.00 0.00 Calibrate 0.00 0.00 0.00 0.00 24.00 Laser Weld 0.00 0.00 8.00 0.00 0.00 Vacuum bake/tig weld 0.00 8.00 0.00 0.00 0.00 Leak check 0.00 8.00 0.00 0.00 0.00 Code 0.00 16.00 0.00 0.00 0.00 Temp Test 0.00 0.00 40.00 0.00 0.00 Creep Test 21.46 0.00 0.00 0.00 0.00 Hypot Test 16.00 0.00 0.00 0.00 0.00 Bend Terminals 8.00 0.00 0.00 0.00 0.00 Weld Wire Leads 0.00 3.22 0.00 0.00 0.00 Tin Dip 0.00 0.00 6.44 0.00 0.00 Weld Connector 0.00 8.00 0.00 0.00 0.00 Inspection/ Writeup 0.00 0.00 0.00 0.00 54.39 111 ShiShiShi ft 3 ft 2 ft 1Description of the LP Model Constants/Inputs • Number of days per month • Demand • Fraction • Current work force • Number of work stations • Max capacity per hour peroperation • Second and third shift fixed cost OPERATION F(fraction) A(#of stations) Units/hr Sort Pins 1 5 500 Weld contact to Header 1 1 180 Weld contact to Arm 1 1 180 Weld Arm to Header 1 1 180 Disc Assemble 1 1 720 Calibrate 1 3 120 Laser Weld 1 1 180 Vacuum bake/tig weld 0.4 1 60 Leak check 1 1 300 Code 1 2 120 Temp Test 1 5 60 Creep Test 1 3 180 Hypot Test 1 2 180 Bend Terminals 0.4 1 180 Weld Wire Leads 0.1 2 120 Tin Dip 0.1 1 60 Weld Connector 0.15 1 60 Inspection/ Writeup 1 5 60Description of the LP Model Constraints • Labor demand per day • Machine capacity per shift • Number of workers for each shift • Work hours by each grade vs. the available number of work hours at each grade level • Non-negativity constraints for decision variables Objective Function To minimize the overall daily staffing cost of production. The cost is calculated by adding up the cost of labor on each operation per shift.Our Integer Model Foray • Disadvantage of LP Model: Fractional work hours (not standard 8 hr employee shift) • Modification of LP Model to create an Integer Model: Number of workers added as decision variables and they were forced to be integers • Disadvantage of the Integer Model: When demand increased (beyond 1-shift) model ran for too long without producing an optimal solutionSupervisor Inputs Monthly Demand Current Workforce LP Model Outputs Model # of Work Days In Month Paycode Specific Staffing Hours: by-shift hours/location required by each paycode Operation Specific Staffing Hours: by-shift total hours of each shift on each individual operation. Overall Paycode Staffing Hours: total staffing hours for each paycode Overall Shift Staffing Hours: total staffing hours on each shift used by management & facilities to gauge level of operation for each shift. Daily and Monthly Staffing Costs: lowest cost per day/month for staffing given current factory constraints.Factory Manager Input/Output Interface Entered Data # Of Work Days In Month 22 InputsMonthly Demand 45000 Existing Workforce Paycode 1 Paycode 2 Paycode 3 Paycode 4 Paycode 5 Head Count 0 0 5 5 7 Decision Variables 4.09 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 r 8 0.00 0.00 0.00 8.00 0.41 0.00 2.95 0.00 0.00 8 0.00 8.00 0.00 0.00 3.36 0.00 0.00 0.00 0.00 r 8 0.00 0.00 0.00 8.00 3.36 0.00 0.00 0.00 0.00 8 2.84 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 17.45 0.00 0.00 0.00 0.00 7 0.00 0.00 4.05 2.95 0.00 2.50 0.00 0.00 0.00 V g8 0.00 8.00 0.00 0.00 5.64 0.00 0.00 0.00 0.00 8 0.00 6.82 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 16.00 0.00 0.00 1.05 0.00 0.00 0.00 0.00 p40 0.00 0.00 24 11.36 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Hy16 11.36 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 8 4.55 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 6.82 0.00 0.00 0.00 0.00 0.00 0.00 0.00 8 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 8 0.00 8.00 0.00 0.00 2.23 0.00 0.00 0.00 0.00 0.00 0.00 34.09 0.00 0.00 0.00 0.00 0.00 0.00 34.20 53.64 38.14 36.41 2.50 0.00 0.00 /gg g Paycode 1 Paycode 2 Paycode 3 Paycode 4 Paycode 5 Paycode 1 Paycode 2 Paycode 3 Paycode 4 Paycode 5 Paycode 1 Paycode 2 Paycode 3 Paycode 4 Paycode 5 Sort Pins 40 0.00 0.00 0.00 0.00 0.00 0.00 Weld contact to Heade0.00 0.00 0.00 0.00 0.00 0.00 Weld contact to Arm 0.00 0.00 0.00 0.00 0.00 0.00 Weld Arm to Heade0.00 0.00 0.00 0.00 0.00 0.00 Disc Assemble 0.00 0.00 0.00 0.00 0.00 0.00 Calibrate 24 0.00 0.00 0.00 16.64 0.00 0.00 0.00 Laser Weld 0.00 0.00 1.86 0.00 0.00 0.00 acuum bake/ti weld 0.00 0.00 0.00 0.00 0.00 0.00 Leak check 0.00 0.00 0.00 0.00 0.00 0.00 Code 16 0.00 0.00 0.00 0.00 0.00 0.00 Tem Test 34.09 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Creep Test 0.00 0.00 0.00 0.00 0.00 0.00 pot Test 0.00 0.00 0.00 0.00 0.00 0.00 Bend Terminals 0.00 0.00 0.00 0.00 0.00