Steve Napier of MMTC discusses how simulation and Lean Six Sigma is used to improve processes and talks through an example in manufacturing of loading and unloading at a paint line.

1. MICHIGAN MANUFACTURING TECHNOLOGY CENTER
MMTC is an affiliate of the NIST Manufacturing Extension Partnership (MEP) and supported by the Michigan Economic Development Corporation (MEDC).
Utilizing Simulation
in Lean Six Sigma
April 9th, 2014

2. MICHIGAN MANUFACTURING TECHNOLOGY CENTER
Steve Napier
©2014 MMTC
 Over 20 years of software and hardware-in-
the-loop simulation
 Full motion flight simulator
 Automotive vehicle testing
 Hardware/software product development
 Current Applications – Lean Six Sigma
consulting, Process Improvement
 BS/MS Engineering
 Plymouth, Michigan

3. MICHIGAN MANUFACTURING TECHNOLOGY CENTER
Michigan Manufacturing Technology Center (MMTC)
Plymouth, MI
 Since 1991, MMTC has assisted Michigan’s small and medium-sized
businesses compete and grow.
 Serve more than 500+ companies annually
 30+ employees and 10+ practitioners
 Directly assist industry clients with growth, continuous improvement,
and compliance
 Supported by the Michigan Economic Development Corporation as Michigan's
National Institute of Standards and Technology Manufacturing Extension
Partnership (MEP) affiliate, we bring well-tested services to our MEP clients.
© 2014 MMTC 2

4. MICHIGAN MANUFACTURING TECHNOLOGY CENTER
Visualizing the Effect of Change
© 2014 MMTC
 The Lean Six Sigma service line helps clients improve
operations by reducing waste and defects
 Sometimes we provide specific ideas that would be
beneficial, but the client can’t let go of the status quo
 Simulation gives us the opportunity to demonstrate the
process changes
3

5. MICHIGAN MANUFACTURING TECHNOLOGY CENTER
Scenario – Loading a Paint Line
A continuous paint line with a very complex mix of parts
 Approx. 100 unique parts, up to 142 racks per day
 80 sec cycle time, 581 racks per day, high & low bake temperatures
 Time to load racks - Min: 30 sec Max: 6 min Weighted Ave: 2.6 min
 Time to unload - Min: 1.7 min Max: 19.3 min Weighted Ave: 9.2 min
© 2014 MMTC 4

6. MICHIGAN MANUFACTURING TECHNOLOGY CENTER
Starting Point
©2014 MMTC

7. MICHIGAN MANUFACTURING TECHNOLOGY CENTER
SIMUL8 Software Model Demo
Demonstrated the process
complexity using a simple model
of the load, paint and unload
The model confirmed the number
of stations and employees
needed to maintain an 80 sec
cycle time
© 2014 MMTC 5

8. Alternate Configuration
MMTC
• Developed using cues from the existing AutoCAD® models
• Incorporates material handling racks for the containers
• Frames or racks are populated in lanes and loaded onto the conveyor
7
Incoming Material Handling Lane Office
2040 sq. ft.
Lane for Unpainted Carts Office
1104 sq. ft.
Material Handling Lane
Office
1578 sq. ft.
Material
Handling/
Pedistrian
Lane
Office
1458 sq. ft.
Material
Handling/
Pedistrian
Lane
Office
1092 sq. ft.
Lane for Painted Carts Office
1104 sq. ft.
Unpainted Material
Container Flow Racks
Empty Container
Flow Racks
Painted Material
Container Flow Racks
Corridor
PaintLineConveyor
Sequence
Coordinator
Finished Goods
Person 1
Warehouse
Warehouse
5 Day WIP Storage
140 ft x 16 ft 4 high 4 deep
Office
2240 sq. ft.
WIP Material Handling Lane Office
1680 sq. ft.
Warehouse
Rack Storage Office
1000 sq. ft.
Final
Audit
Office
605 sq. ft.
Finesse
Office
242 sq. ft.
Painted Material Handling Lane
Office
1680 sq. ft.
Office
120 sq. ft.