Use of Physical Simulation, Computer Simulation and a Common Product in a Series of Courses to...

Use of Physical Simulation, Use of Physical Simulation, Computer Simulation and a Computer Simulation and a

Common Product in a Series of Common Product in a Series of Courses to Illustrate Industrial and Courses to Illustrate Industrial and

Manufacturing Engineering Manufacturing Engineering Technology PrinciplesTechnology Principles

Tom Carlisle – Professor Industrial Tom Carlisle – Professor Industrial Engineering Technology, Sinclair Engineering Technology, Sinclair Community CollegeCommunity College

Charles Winarchick – Associate Professor Charles Winarchick – Associate Professor Industrial Engineering Technology, Sinclair Industrial Engineering Technology, Sinclair Community CollegeCommunity College

Charlie is sorry he couldn’tCharlie is sorry he couldn’tbe here today, but wanted to say hello.be here today, but wanted to say hello.

Charlie and I wish to thank the conference Charlie and I wish to thank the conference sponsors for the opportunity to make this sponsors for the opportunity to make this presentationpresentation

NJCATE - A National Center for advanced NJCATE - A National Center for advanced Technological EducationTechnological EducationNCME – National Center for Manufacturing NCME – National Center for Manufacturing EducationEducationMATEC – Maricopa Advanced Technologies MATEC – Maricopa Advanced Technologies Education CenterEducation CenterFL-ATE – Florida Advanced Technological FL-ATE – Florida Advanced Technological Education CenterEducation Center

We Wish To ThankWe Wish To Thank

I hear and I forgetI hear and I forget

I see and I rememberI see and I remember

I do and I understandI do and I understandConfuciusConfucius

“…“…all forms of action learning share the all forms of action learning share the elements of real people solving and taking elements of real people solving and taking action on real problems in real time and action on real problems in real time and learning while doing so.”learning while doing so.”

Marquardt – Harnessing the Power of Action Marquardt – Harnessing the Power of Action Learning”Learning”

Sinclair Community CollegeSinclair Community College– Home of National Center for Manufacturing Home of National Center for Manufacturing

EducationEducation

NCMENCME

Authentic Learning TasksAuthentic Learning Tasks– Replicate real world applicationsReplicate real world applications– Focus on Building Specific skills and Focus on Building Specific skills and

competenciescompetencies– Closure and generalizationsClosure and generalizations

Physical SimulationPhysical Simulation

Materials – K’Nex building materialsMaterials – K’Nex building materials


Materials – K’Nex building materialsMaterials – K’Nex building materials– StrengthsStrengths

Simple to useSimple to useReadily availableReadily availableCan be configured to produce any number of Can be configured to produce any number of different productsdifferent productsReusableReusableInexpensiveInexpensive

– WeaknessWeaknessCan only be used to simulate assembly operations Can only be used to simulate assembly operations

Controlled Access Timer BoxesControlled Access Timer BoxesCAT BoxCAT Box

CAT BoxCAT Box

Parts SpitterParts Spitter


Create a ProductCreate a Product

Link to CoursesLink to Courses

This product and the information relayed to it is used in:This product and the information relayed to it is used in:IET 101 – Work Methods Analysis and ImprovementsIET 101 – Work Methods Analysis and ImprovementsIET 111 – Work Measurement TechniquesIET 111 – Work Measurement TechniquesIET 115 – Survey of Production and Inventory controlIET 115 – Survey of Production and Inventory controlIET 130 – Lean ManufacturingIET 130 – Lean ManufacturingIET 207 – Manufacturing System AnalysisIET 207 – Manufacturing System AnalysisIET 135 – Manufacturing Cost AnalysisIET 135 – Manufacturing Cost Analysis

Course ContentCourse Content

IET 101 Work Methods Analysis and IET 101 Work Methods Analysis and ImprovementImprovement– Plan-Do-Study-Act (PDSA) CyclePlan-Do-Study-Act (PDSA) Cycle– ProductivityProductivity– Process Flow Chart and Flow DiagramProcess Flow Chart and Flow Diagram– Pareto AnalysisPareto Analysis– Cause and Effect (Fishbone) DiagramsCause and Effect (Fishbone) Diagrams– BrainstormingBrainstorming

Course ProjectCourse Project

IET 101 Work Methods Analysis and IET 101 Work Methods Analysis and ImprovementImprovement– Teams of from 4 to 8 students Teams of from 4 to 8 students – Goal- build as many wagons as possible in 30 Goal- build as many wagons as possible in 30

minutesminutes– Start with a given “less than ideal” processStart with a given “less than ideal” process– Spend the term working on and implementing Spend the term working on and implementing

improvementsimprovements– Last class- formal presentation and Last class- formal presentation and

demonstrationdemonstration

ProductProduct

Project ImprovementsProject Improvements

Ideas generated by team are Ideas generated by team are communicated to IE lab technician who communicated to IE lab technician who produces needed fixtures and toolingproduces needed fixtures and tooling

This simulates the use of a maintenance This simulates the use of a maintenance department in a plantdepartment in a plant


IET 111 Work MeasurementIET 111 Work Measurement– Effective work motionsEffective work motions– Work methodsWork methods– Basic ErgonomicsBasic Ergonomics– Time study and Work Standards Time study and Work Standards – Introduction to MTMIntroduction to MTM– Motion KaizenMotion Kaizen– Workplace designWorkplace design


IET 111 Work MeasurementIET 111 Work Measurement– Design an “effective” workplace using the Design an “effective” workplace using the

K’nex wagonsK’nex wagons– Use workplace holding fixtures to do Use workplace holding fixtures to do

progressive build-up of wagonsprogressive build-up of wagons– Class broken into 4 teams (one for each Class broken into 4 teams (one for each

station)station)– Construct, run, time and determine standardsConstruct, run, time and determine standards– Demonstrate and report during last classDemonstrate and report during last class

ProductsProducts

FixturesFixtures


IET 115 Production & Inventory ControlIET 115 Production & Inventory ControlB.O.M.sB.O.M.s

Push vs. Pull systemsPush vs. Pull systems

Routings and schedulingRoutings and scheduling

Capacity forecasting and planningCapacity forecasting and planning

KanbansKanbans


IET 130 Lean ManufacturingIET 130 Lean ManufacturingValue Stream mappingValue Stream mapping

Lead Time reductionLead Time reduction

Waste Identification and EliminationWaste Identification and Elimination

ContainerizationContainerization

Standardized Work and Takt TimeStandardized Work and Takt Time

Set-up reductionSet-up reduction

Cell Design and one piece flowCell Design and one piece flow

KanbanKanban


IET 130 Lean ManufacturingIET 130 Lean Manufacturing– Take basic wagon from 101 And 111 and add Take basic wagon from 101 And 111 and add

another model and optionsanother model and options– Use Work Stations from 111Use Work Stations from 111– Add production simulation machines: CAT Add production simulation machines: CAT

Box and Parts SpittersBox and Parts Spitters


IET 130 Lean ManufacturingIET 130 Lean Manufacturing– Students on 4 to 12 person teamsStudents on 4 to 12 person teams– Run to customer demand (Takt Time)Run to customer demand (Takt Time)– Can run 1 or 2 Work cellsCan run 1 or 2 Work cells– One sub-assembly cellOne sub-assembly cell– CAT Boxes and Parts Spitters as neededCAT Boxes and Parts Spitters as needed– Final Class – cell demonstrated using 10 sided die for Final Class – cell demonstrated using 10 sided die for

part distribution probabilitypart distribution probability


IET 135 Manufacturing Cost AnalysisIET 135 Manufacturing Cost AnalysisCosting of products using routing informationCosting of products using routing information

Production and product costsProduction and product costs

Project estimating and job quoting and biddingProject estimating and job quoting and bidding

Computer SimulationComputer Simulation

IET 207 Manufacturing Systems AnalysisIET 207 Manufacturing Systems Analysis– Use of ProModel simulation softwareUse of ProModel simulation software– Design and evaluate increasingly complex Design and evaluate increasingly complex

manufacturing and service processesmanufacturing and service processes– One course project is to physically setup a physical One course project is to physically setup a physical

simulation of a process in our IET labsimulation of a process in our IET lab– Over two to three weeks the students study the Over two to three weeks the students study the

physical simulation and record data needed to physical simulation and record data needed to complete a computer simulationcomplete a computer simulation

– Students then complete a computer simulation of the Students then complete a computer simulation of the processprocess

Computer SimulationComputer Simulation

IET 207 Manufacturing Systems AnalysisIET 207 Manufacturing Systems Analysis– The computer simulation is ran and processes data The computer simulation is ran and processes data

recorded and evaluatedrecorded and evaluated– The students then run the physical simulation and The students then run the physical simulation and

compare results to the computer simulationcompare results to the computer simulation– Discussions concerning the validity and verification of Discussions concerning the validity and verification of

the computer simulation verses the physical reality, the computer simulation verses the physical reality, strengths and weaknesses of computer simulation, strengths and weaknesses of computer simulation, value of both types of simulation and similar matters value of both types of simulation and similar matters take placetake place

As of 5/6/02 File = ZIP/IET-207/Course Notes/Lab Assignments/W-R-U Assy Model-v2 1.xls

Wagons-R-Us Corp.Proposed Assembly LineP/N F-WRN-001, Wagon, Rail Bottom W/ No Side Rails10/4/00

Does final assy & moves wagonsto storage & move tray to Order Entry

Order Arrivals = N(.75,.1) minutes Finished StorageEntry Product capacity

Moves tray Storage is infiniteto Order Input &place trays on conveyor Work

StationOrder Work Work #3-2 FinalInput Skate Conv Station Skate Conv Station Skate Conv Skate Conv Inspection

Station #1 #2 Work StationStation

#3-1

Storage Capacities = Infinite ? 1 ? 1 ? 2 ? 1

Assy. side Assy. pull Assy. tworails, bottom bar, attach axles and dorails & hitch to side rails final assy

& assy tobottom rails

Cycle Times = ? ? ? ?

Future DevelopmentsFuture Developments

Run IET 130 and IET 207 concurrentlyRun IET 130 and IET 207 concurrently

IET 207 students will do a computer IET 207 students will do a computer simulation of the work cell arrangement in simulation of the work cell arrangement in designed in IET 130designed in IET 130

ResultsResults

By using the same family of products in By using the same family of products in several courses students begin to several courses students begin to understand how different concepts and understand how different concepts and techniques taught in different courses are techniques taught in different courses are interrelatedinterrelated

ResultsResults

Survey of 173 students who answered the Survey of 173 students who answered the question “ The lab component of this question “ The lab component of this course assisted me in learning the subject” course assisted me in learning the subject” showed:showed:– 64.7% Strongly Agree64.7% Strongly Agree– 20.8% Agree20.8% Agree

ResultsResults

Selected comments (no unfavorable comments Selected comments (no unfavorable comments received):received):– ““The wagon project is an excellent way to show how The wagon project is an excellent way to show how

to use what we learned”to use what we learned”– ““I liked the hands on experience, rather than just I liked the hands on experience, rather than just

sitting in a class room going over movies or reading sitting in a class room going over movies or reading out of a book”out of a book”

– ““Very hands on and real world related”Very hands on and real world related”– ““Fun. It was fun.”Fun. It was fun.”

Questions?Questions?

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