Magical Lantern

FINAL REPORT
Improvement Demand and Service Level
Fabre-Surinon

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 Final Report 2010

Sommaire
I. First mission .......................................................................................................................................... 3
A. Model of the system ......................................................................................................................... 3
B. Improve the production to reach 1100 units per week .................................................................... 7
C. Improve the production to reach 1250 units per week .................................................................... 7
II. Second mission ..................................................................................................................................... 9
A. Model of the demand ....................................................................................................................... 9
B. Results ............................................................................................................................................. 11
C. Improvement .................................................................................................................................. 12

ANNEXE
Assumption report

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 I. First mission
A. Model of the system
i. Flow scheme simplified

Figure 1 Flow scheme simplified

 Final Report 2010
ii. Model of the raw cable section

In this section we had to respect two constraints:

- Start the production of the bundle only if size of the finished bundles stock is below 60
units.

Condition in the raw cable create: Number_in_Queue(Wiring operation) <= 60

- Product the bundles in lot of 300 units, and send those once all are prepared

Create raw cable by 300 units, batch 300 units and then separate in 300 units

iii. Model of the chip’s KANBAN

Once chips are created, they era part of a KANBAN system. To make a model of that we choose:

1°/ To create single chip, creation follow this expression: 40+UNIF (3, 37)

2°/To use the trick Match-Separate to simulate KANBAN system.

iv. Model of the dwarf’s KANBAN

In order to model the dwarf’s KANBAN, we decided to create only the KANBAN Number and
to make a loop with a separate at the end of the product line. We also had to recalculate the
KANBAN Number (N=Demand*Loop_length/Capacity). So we calculate the length of the loop with a
box readwrite, which gives us the entering time and the living time of the system for each dwarf.

Thus we find N=127.

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v. Model of the delay

To model the delay we drawn the following system:

Figure 2 Scheme of the delay

The only constraint is to create one “delay” at the start of the simulation, so that the first dwarf is
able to go through the match box.

vi. Simulation’s parameters

We first calculated the warm-up period. In order to do so we made a simulation with 10

replications of one day (8 hours). We did the simulation on only one day, because each day the
production line has to be launched, so each day faces a warm-up period. We get the data from the
system, by using two readwrite boxes. The first gives the number of dwarf which is made per semi
hour, the second gives the current time of the simulation.

Figure 3 Scheme make to get data

So we obtained the following results:

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Evolution of the production capacity

per semi hour
18
16
14
12
10
8
6
4
2
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Average

After having analyzed the data we estimated the warm-up period at 3 hours.

Then we search the number of replication. To do so we made ten simulations, with a number
of replication from one to ten. We then calculated the average of the dwarf created.

Number of Number of
repilcation dwarf
created
20 1023,55
10 1024,1
9 1024,56
8 1023,88
7 1024,86
6 1025,5
5 1024,6
4 1025
3 1025,67
2 1022
1 1033

Average 1024,35

After having analyzed the data we estimated that a good number of replication was 10.

Finally our model is able to produce around 1024 units per week. We believe that the difference
between our model and the real system (average of production per week is 1040 for the real system)
is due to the fact that the real system is launched at its full capacity.

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B. Improve the production to reach 1100 units per week
The first goal of the first mission was to increase the weekly production to 1100 units. So as the
demands arose, we first recalculate the number of KANBAN to fit with the new demand.

Objectives Demands Length K Capacity N Length K Capacity N

per hour chip chip chip chip dwarf dwarf dwarf dwarf
1100 27,5 1 0 1 28 4,87 0 1 134
1250 31,25 1 0 1 32 4,87 0 1 153
1040 26 1 0 1 26 4,87 0 1 127

These sole modifications were enough and so we reach this objective:

1102.2 dwarfs per week (average on 10 replications)

C. Improve the production to reach 1250 units per week

Despite the increase in number KANBAN, the production per week was not enough (1117.5).
So we analyzed the report of simulation and found that the paint shop was a bottle neck station.

Thus we choose to add a resource. But it the production was still not enough (1213.6). As the
demand increase so does the work in each station. So in order to prevent any strike from the labor
force, we choose to add an operator in the assembly lantern station:

 Delay between dwarf: 1min 38s and Conveyor belt speed: 0.75 km/h

Finally this last modification enables us to product more than 1250 dwarf per week.

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Objectives Demands Increase N Ressource added Operator added in
Paintshop Assembly lantern
1100 27,5 1102,2
1250 31,25 1117,5 1213,6 1252,7
1040 26

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II. Second mission

A. Model of the demand

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Figure 4 Model of the demand section
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i. Delayed demand
We create an entity which follows a normal law (1, 1/6). This entity is store in a
“hold” with the following condition: “hold the command while the second hold (c.f
below) is up to 0”. It permits us to know the numbers of delayed command. We also
placed a record in order to know the total number of demand.

Figure 5 Model of the delayed demand

ii. Waiting demand

A second hold stores the lot size of each the first waiting command while there is
not enough dwarf in the queue of the “match 6”.

Figure 6 Waiting demand

iii. Lot size

We use a “separate” which split each command in a lot size determinate by the
Uniform law (5, 45).

Figure 7 Creation of the lot size

iv. Delivery system

We made it with the “match 6” which associates the lot size of the command
with the current production of dwarfs. We also move the “separate 9”, which
symbolize the liberation of the kanban attached to the dwarfs, after the realization
of a command: It means we liberate the kanban ticket after the delivery of a dwarf.

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Figure 8 Delivery System

B. Results
We use a read write, which write the number of waiting demand in the
queue of the first hold.

Then we divide this number (paying attention to remove the number of

waiting demand during the warm up period) by the total number of demand.
For the first simulation we had a level service of 97.7% with a warm up
period equals to 13 hours, and a replication length of 80 hours

Total demand
delayed 16
Total demand per
replication 69,2
Number of
replication 10
Service level 97,7
Tableau 1First set of results

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C. Improvement
We calculate a new cycle time of 5.75 hours so we calculate a new numbers
of Kanban of 180, and we obtained a service level of 100%.

Objectives Demands Length K Capacity N

dwarf dwarf dwarf dwarf
1100 27,5 5,75 0 1 159
1250 31,25 5,75 0 1 180
1040 26 5,75 0 1 150

Number of
demand delayed 0
Average number
of demand
delayed 1073,8
Number of
replication 10
Service level
100
Tableau 2 Second set of results

We are surprised of this value because we excepted some delayed commands but even after
a check of our model everything seems to be normal.

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