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Jai Hind Cycle Inc.

Jai Hind Cycle Inc. Presented By: Mike Seide Sean McCauley Matt Zbylut Rebecca Gramse. Introduction. Jai Hind Cycles produces bicycles and is planning on introducing a new model of mountain bike strictly for the export market

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Jai Hind Cycle Inc.

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  1. Jai Hind Cycle Inc. Presented By: Mike Seide Sean McCauley Matt Zbylut Rebecca Gramse

  2. 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

  3. 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

  4. 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

  5. Building the As-Is Model

  6. 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

  7. 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

  8. Building the To-Be Model

  9. FMS Used in Model • Cellular Manufacturing Layout • Use of simple machines, no custom jigs • Use of AGVS for transportation • Cross Trained Workforce

  10. 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

  11. 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

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