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- Project 6 Team
- Phil Coady, Joe Cremaldi,
- John Deas, Steve Escaravage
- February 18, 2009
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- Problem Statement: Current insert
production planning process is inefficient, labor intensive, and does
not account for new equipment constraints and capabilities
- Scheduling is only partially automated
- Requires manual hopper selection, assembly line mapping, and job
assignments
- Requires long lead-times to produce schedules
- Collator operation has multiple inefficiencies
- Feeding FSIs into collator is labor intensive
- Changing hopper contents for the next IPC is time and labor intensive
- Takes up to 3 minutes to change hopper contents
- Usually 250 - 300 IPCs per Sunday
- Line must stop during change-over causing labor loss
- Introduction of new collator requires process change
- Current planning process does not account for changeover implications
of new collator machine
- New collator provides physical performance enhancements
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- Design Schedule Optimizer Module
- Develop algorithms to optimizes job (IPC) scheduling and hopper
assignment for Sunday inserts
- Minimize changeover requirements and time
- Minimize total production time
- Minimize resource requirements
- Meet all production deadlines
- Secondary goals
- Identify required computer hardware
- Define software interfaces
- Document functional and physical architectures, software
specifications, and provide user manuals
- Verify system design using modeling tools
- Other tasks
- Develop business case analysis to determine pricing
- Recommended replacement collator physical configuration
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