Rensselaer Polytechnic Institute Simulation and Analysis of a Pratt & Whitney Turbine Module Manufacturing Cell Christopher L. Gunther Rensselaer Polytechnic Institute DSES-6620 Simulation Modeling and Analysis Final Presentation 21 December 2000 Hartford, Connecticut

Rensselaer Polytechnic Institute Executive Summary Goal: Simulate Manufacturing Cell #6 –Build a ProModel simulation of the system –Determine the limit production load of the cell –Identify potential areas for improvement Baseline model with current production level –Verify/validate simulation model –Understand the process and resource utilization Difficult due to long cycle times, shifts, and operators Production run results for 7 production levels analyzed –Current three-month requirement of 35 parts correlates well –Cell reaches saturation point at around 44 parts/three months –More VTL machines can improve throughput (long operation times) –More operators needed (manual machine and move time)

Rensselaer Polytechnic Institute Current Process Layout

Rensselaer Polytechnic Institute Machine Capacity by Process - Improved

Rensselaer Polytechnic Institute Determination of Cell Capability

Rensselaer Polytechnic Institute Simulation Results

Rensselaer Polytechnic Institute ProModel Simulation Manufacturing Cell #6 layout copied Machines and operations labeled –Operator manual internal and external time –Machine automatic time –Setup time Uncertainty introduced into the model –5% normal distributions used on all times –Random operator downtime Gray boxes are queues with counters Two operators with idle and downtime locations Global variable created to count exits DEMO!DEMO!