Jai Hind Cycle Inc.

Presented By:Mike SeideSean McCauleyMatt ZbylutRebecca Gramse

Introduction

Jai Hind Cycles produces bicycles and is planning on introducing a new model of mountain bike strictly for the export market

The company currently runs one shift per day and is considering replacing their existing factory layout with a cellular, group technology layout

Assumptions

Production at 82,000 units would be interpreted as 328 bikes per production day Of those 328 bikes, 200 would be regular bikes and 128

would be mountain bikes 250 work days/year; 2080 work hours/year; 8 hour

work days Anything not produced is sub-contracted or

purchased from the market for the final assembly A 100 hour warm-up period was used to reach

steady state

As-Is Model

Job shop facility layout Current Production of 200 regular bikes per

day High quantity of casting and final assembly

machines Inefficient workspace

Building the As-Is Model

To-Be Model Assumptions AGVS speed is set to a maximum of 5 mph Human workers will transport the goods between

stations Human worker speed empty is 300 fpm and full is

250 fpm The operators and AGVS will return home when idle Production runs two 8 hour shifts per day AGVSs are used to transport raw materials from

Raw Material Receiving/Storage to the designated queues.

Each cell contains 1 machine of each type

To-Be Model

Incorporated Group Technology with Cellular Manufacturing Part Families, like characteristics

AGVS Delivering raw materials to cells

Workers Path network, constantly moving to different cells

for assistance or assembly

Building the To-Be Model

FMS Used in Model

Cellular Manufacturing Layout Use of simple machines, no custom jigs Use of AGVS for transportation Cross Trained Workforce

To-Be Model Results

Bottlenecks Frame cell and Handle Bar cell was over utilized Reduced by adding cells to both

Production increased to 333 bikes per day Reduced labor by adding AGVS delivery

system of raw materials Reduced # of workers by incorporating

floating worker design

Recommendations

Implement the Group Technology Cellular Manufacturing layout

Add capacity to the frame and handle bar cells

Use AGVS to reduce workers and increase efficiency

Use workers to transport materials between cells