simulation for analyzing trolley operator...
TRANSCRIPT
SIMULATION FOR ANALYZING TROLLEY OPERATOR UTILIZATION & AISLE CONGESTION MEASUREMENT
www.steadfastglobal.com
One of the largest two wheeler manufacturers and exporters in India was interested in building a simulation model as part of its continuous improvement strategy. They wanted to simulate the Scooter assembly unit replenishment
operation between Storage unit and assembly unit using Flexsim
Software. This is to help them understand the current situation
and help towards a larger goal to optimize operator requirements
and to ensure optimum availability of material to achieve
production targets.
Key objectives of the FlexSim simulation would be
Identify the trolley operators utilization
Identify the traffic\congestion during the parts
replenishment on the assembly unit
Operators and Trucks in Aisle
Operators and Trucks
Type of Project Client Engagement Size Technology/Tools Industry Users
Outsourced Simulation
Model Development
Developed and delivered for the Production Engineering Department of one of the
largest two and three wheelers manufacturer and
exporter in India.
2 person months
Flexsim Manufacturing Production Engineering Department
Industrial Engineers
Project Profile
Special notes
High Number of Parts Types to be Handled (168 Part Types) High Variability In Routing And Material Flow And Operator Sequence Development of Trolleys and Trucks For Simulation Encapsulating All Operational Aspects Of The material Movement in the plant Comprehensive Analysis of the Traffic Congestion in Main Aisle
Other details
A development involving extensive of C++ code Keep on Communicating with client and collect all the requirement, operational
flow and information to simulate the exact floor operation. Each assumptions will be documented immediately and confirm the same with client to avoid the last minute surprise.
Key Business Benefits
• User can extend this model to other areas of the floor and integrate
other operations
• Very easy to make decisions on the floor operation either they would
require more number of resources or not
• Very easy to measure the Aisle congestion and Operator utilization
Summary:
Project was divided into different phases and implemented using the following
methodology and delivered on time.
Flexsim Simulation Implementation Methodology
Initiation Data Collection Solution Design Build the simu-
lation model Analysis
Delivery and action plan
Understand the simulation Goals and objectives Requirement Analysis for simulation. Collect operation details, process flow, machine data etc. Tour existing Facility and collect info if required Prepare the process flow, scope and assumption docs Review and confirm
Share the CAD layout of the plant which needs to be simulated List Compo-nents\ Resources of the system and collect the operation details. List all the questions and clarify with customer (Continuous activity between Steadfast and Customer until clarity)
Mapping the requirement with Flexsim Functionalities Design to bring in the data (e.g. tripsheet , path, speed etc) into the model Design the cod-ing components (triggers, timers, rules etc) Design the traffic rules Design the break times and scheduled breakdowns (logic for rules)
Design to consider Memory utilization while handling high number of parts. Establish basic parameters for the simulation and import CAD layout Layout objects on the screen, connections, path (simulation surface) Implement coding logic Implement the reports and dashboard
Validate and Verify the Simulation Model Add variables to capture the additional metrics Design and Run Experi-ments Analyse Simulation Outputs
Draw conclusions, present results and recommen-dations
Gaining In-formation and decision making based on reports im-plemented in the model.
P R O J E C T M A N A G E M E N T (Schedule, Resource, Customer expectation Management)
Customer Steadfast
PROJECT METRICS
0 10 20 30 40 50 60 70 80 90
Result Verification and Analysis With Client
Coding & Delivery
High Level Design
Model Layout Design and Flow Confirmation
Requirement Analysis
Actual Vs Planned - Man Hours
Actual Man Hours Planned Man Hours
0 2 4 6 8 10 12
Result Verification and Analysis With Client
Coding & Delivery
High Level Design
Model Layout Design and Flow Confirmation
Requirement Analysis
Actual Vs Planned - Calendar Days
Actual Calender Days Planned Calender Days
If you are a sophisticated, market facing company with a need for designing and implementing software solutions to solve real world business problems, or if you are a Software Service or Product Company in the US, looking for a reliable and committed long-term partner, you have come to right place. We are looking for clients whose annual software budget is in excess of USD 100,000.
Our vision is to become a 100 people company by 2020, operating from India, with an average revenue per employee of USD 100,000 P.A.
boutique software consulting company. We design and implement software solutions to real world business problems.
ABOUT YOU
Lead by a team of 3 senior technocrats and 6 mid-level project managers we have the right mix of resources to take up projects in the range of 10 people months to 100 people months. Our current technical skills are in Salesforce, NetSuite, MEAN and Microsoft Technologies. For skills other than these, we will outsource the coding part to our vendors in India while taking complete responsibility for the project design and delivery.
ABOUT US
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www.steadfastglobal.com