Cebu Institute of Technology

University
N. Bacalso Avenue, Cebu City, Philippines

COLLEGE OF ENGINEERING AND ARCHITECTURE

A Case Study Report on

TOY AIRPLANE MANUFACTURING COMPANY
Presented to the Faculty of Industrial Engineering Department
Cebu Institute of Technology - University, Cebu City, Philippines

In Partial Fulfillment
of the Requirements for the Degree of
BACHELOR OF SCIENCE IN INDUSTRIAL ENGINEERING

By:

ERIKA A. ALBUERA
DARLA MAE P. CASERO
RYAN EUSEBIO
ANGELA KLARA B. RUEDT

2nd Semester Academic Year 2021-2022

1. Introduction

1.1 Rationale

Modern manufacturing is characterized by high levels of automation and

integration, complex interactions among system elements, and high capital costs. While

modeling and analysis are important to help ensure good system performance, the

integration and complexity of systems often makes purely analytic tools difficult to use.

Hence, simulation remains one of the most widely used tools to fill this need [1].

Simulation is the imitation of the operation of a real-world process or system over time

Simulation modeling is a method of resolving real-world problems in a safe and

effective manner. It provides a safe way to explore different options to be able to make

the right decision before making real-world changes. Virtual investigations using

simulation models are less expensive and time consuming than real-world experiments,

with only the use of lesser resources. Simulation is frequently the technique of choice in

problem solving. Simulation is also being used to study systems in the design phase

before such systems are built so that the problem may be identified and resolved well

before implementation [2].

Many manufacturing firms use computer simulation to plan, develop, execute, and

study manufacturing system problems of interest. Manufacturing systems are also

frequently designed using simulation modeling. Simulation has been widely used in the

manufacturing industry as a technique of modeling the system and attempting to model

the impact of variability on system behavior as well as exploring various strategies to cope

with changes and uncertainty [3]. Using a valid simulation model gives several benefits
and advantages in developing a better system and in predicting the system behavior

under varying set of circumstances to improve the system performance.

[1] D. A. Bodner and L. F. McGinnis , “A Structured Approach to Simulation Modeling of

Manufacturing Systems .”

[2] J. Banks, “INTRODUCTION TO SIMULATION.”

[3] C. M. L. RAHMAN and S. U. SABUJ, “PROCESS FLOW IMPROVEMENT

PROPOSAL OF A BATCH MANUFACTURING SYSTEM USING ARENA SIMULATION
MODELING .”

1.2 Objective of the Study

The main objectives of this study are the following:

● To show the process of the existing operation by the toy airplane manufacturing

company.

● To analyze the existing process of the toy airplane manufacturing company.

● To present the total number of machines and personnel needed in meeting the

requirements of the company.

1.3 Scope of the Study

Place Delimitation

This study is virtually conducted in Cebu City, Philippines, 6000.

Time Delimitation
 This study will take place between November 23, 2021 and December 9, 2021

which is the second cluster of Academic Year 2021-2022 of Cebu Institute of Technology

– University.

COVID-19 Pandemic Delimitation

As a result of the COVID-19 pandemic-related restrictions, this study will be

conducted virtually. The face-to-face set-up was momentarily transformed into an online

set-up in which the CIT University strictly follows through the foundation MADE4Learners

Framework. This framework is designed to enable the students to still be creative and

innovative under the new normal using the Technology Support Tools in the comforts of

their homes.

Subject Delimitation

The focus of the researchers is solely on the manufacture of the Toy Airplane. The

existing set up of the manufacturing company will be analyzed for the provision of

solutions, conclusions and recommendations. Specifically, the total number of machines

and personnel needed to meet the daily requirements of the company will also be

presented.

1.4 Brief Description of the Study

A Toy Airplane Manufacturing Company offers 3 types of toy airplanes, specifically

producing; Plane A=1000, Plane B=1500, and Plane C= 1800. For the next six months

the company expects demand to increase by 30%. With the company’s conditions and
existing process, this study will provide the total number of machines and personnel in

order to reach the company’s expectations.

1.5 Significance of the Study

· Toy Manufacturing Companies

This study will provide an actual simulation of the descriptive (existing) phase of

the company and prescriptive suggestions of the researchers using Promodel 7.5 for a

precise presentation. Companies can get an idea on how to make their production more

efficient than their existing process.

· Researchers

This study will provide a learning experience for the researchers as they will

provide solutions to the company’s problem and will present it using a simulation

model.

· Future Researchers

The future researchers can further improve the current study by filling the gap.

They will also gain some insight from this research on how to provide answers and

recommendations to problems that are presented to them on a regular basis,

production-wise.

Descriptive Phase (Existing)

Below is a toy manufacturing case that needs to be analyzed and simulated.

ASSUMPTIONS

The following statements are the assumptions for the study:

1. 1 output from the die casting machine = 6 airplanes

2. 1 batch size = 6 airplane

3. 24 batch size = 144 airplanes

4. The batches are grouped in same airplane types

5. The production is on-going for 8 hours, no breaks.

 6. The inspection and packaging area is run by a machine.

7. 88% is the efficiency of each machine.

8. The inspection and packaging is per batch.

Diagnostic Phase (problem analysis)

NUMBER OF MACHINES FOR THE EXISTING OPERATION

Hours required = Time per part x required / efficiency

Hour available per machine = production time x % working time

Number of Machines = Hours required / Hours available

DIE CASTING

4300 airplane / 6 output = 717 raw material needed

Hours required = 3 min / 60 min/ hr x 717 raw material / .88 = 40.74 hours

Hour available per machine = 8 hr x 0.5 = 4 hrs available

Number of machines = 40.74 / 4 = 10.18 or 11 machines

CUTTING

Hours required = .35 min / 60 min/hr x 4300 raw materials / .88 = 28.50 hours

Hours available per machine = 8 hrs x 1= 8 hrs available

Number of machines = 28.50 / 8 = 3.56 or 4 machines

GRINDING

Hours required = .26 min / 60 min /hr x 4300 raw materials / .88 = 21.17 hours

Hours available per machine = 8 hours x 1 = 8 hours available

Number of Machines = 21.17 / 8 = 2.65 or 3 machines

COATING

Hours required = 12 min / 60 min/hr x 3300 raw materials /.88 / 24= 31.25 hours

Hours available per machine = 8 hours x 1 = 8 hours available

Number of Machines = 31.25/8 = 3.91 or 4 machines

INSPECTION AND PACKAGING

Hours required = .40 min / 60 min/hr x 4300 raw materials / .88 = 32.58 hours

Hours available per machine = 8 hours x 1 = 8 hours available

Number of Machines = 32.58/8= 4.07 or 4 machines

In this part of the study the utilization rate will be presented. To sum everything

up, here are the average utilization rate of the machines involved in each operation:

78.57% for Die Casting Machine, 19.26% for the Cutting Machine, 19.1% for the

Grinding Machine, 7.08% for the Coating Machine, 0.63% for the Inspection and

Packaging.
 The average idle percentage of each machine involved in the operation are the

following: 21.43% for the Die Casting Machine, 80.47% for the Cutting Machine, 80.90%

for the Grinding Machine, 92.92% for the Coating Machine, and 99.37% for the Inspection

and Packaging.
The utilization average of the resources are the following: Automated Die Caster is

11.67%, Cutter is 37.41%, Grinder is 35.19%, Coater is 7.59%, Packager is 2.43%,

Repairman is 97.23%, Mover 1 is 3.46%, and mover 2 is 6.2%.

The following are the idle rate average of the resources: Automated Die Caster is

88.33%, Cutter is 62.59%, Grinder is 64.81%, Coater is 92.41%, Packager is 97.57%,

Repairman is 2.77%, Mover 1 is 96.54%, and Mover 2 is 93.74%.

Total outputs for the existing production set-up is 1152 pieces for airplane A , 2016

pieces for airplane, and 2016 pieces of airplane C.

NUMBER OF MACHINES FOR 30% PRODUCTION INCREASE

Total Demands for each airplane type:

Plane A = 1300 pieces

Plane B = 1950 pieces

Plane C = 2340 pieces

TOTAL PRODUCTION OUTPUT: 5590 pieces

5590 airplane / 6 output = 932 raw material needed

DIE CASTING

Hours required = 3 min / 60 min/ hr x 932 raw material / .88 = 52.95 hours

Hour available per machine = 8 hr x 0.5 = 4 hrs available

Number of machines = 52.95 / 4 = 13.24 or 14 machines

CUTTING

Hours required = .35 min / 60 min/hr x 5590 raw materials / .88 = 37.05 hours

Hours available per machine = 8 hrs x 1 = 8 hrs available

Number of machines = 37.05 / 8 = 4.63 or 5 machines

GRINDING

Hours required = .26 min / 60 min /hr x 5590 raw materials / .88 = 27.53 hours
Hours available per machine = 8 hours x 1 = 8 hours available

Number of Machines = 27.53 / 8 = 3.44 or 4 machines

COATING

4290 airplanes = 178.75 = 179 batches

Hours required = 12 min / 60 min/hr x 179 raw materials /.88 = 40.68 hours

Hours available per machine = 8 hours x 1 = 8 hours available

Number of Machines = 40.68 / 8 = 5.085 or 5 machines

INSPECTION AND PACKAGING

Hours required = .40 min / 60 min/hr x 179 raw materials / .88 = 1.35 hours

Hours available per machine = 8 hours x 1 = 8 hours available

Number of Machines = 1.35/8= 0.169 or 1 machine

For the proposed operation of the Toy Airplane Company, the following are the

utilization rate average of the machines involved: Die Casting Machine is 75.44%, Cutting

Machine is 50.45%, Grinding Machine is 38.12%, Coating Machine is 14.84%, and

Inspection and Packaging is 4.67%

 The following are the average idle rates of the proposed operation: 24.56% for Die

Casting Machine, 49.55% for Cutting Machine, 61.88% for Grinding Machine, 85.16% for

the Coating Machine, and 95.33% for Inspection and Packaging.

 The following are the average utilization rate of the proposed method for the

resources: Automated Die Caster is 63.48%, Cutter is 93.90%, Grinder is 74.54%, Coater

is 15.91%, Packager is 4.88%, Repairman is 49.19%, Mover 1 is 2.86%, and Mover 2 is

8.86%.
The idle rate of the resources for the proposed method are as follows: Automated Die

Caster is 36.52%, Cutter is 6.10%, Grinder is 25.46%, Coater is 84.09%, Packager is

95.12%, Repairman is 50. 81%, Mover 1 is 97.14%, and Mover 2 is 91.14%.

Prescriptive Phase

For the prescriptive operation of the machines, the following are the utilization

rate: Die Casting Machine is 80.03%, Cutting is 42.4%, Grinding is 28.13%, Coating is

53.08%, Inspection and Packaging is 1.84%.

The idle rate of the machines are the following: Die Casting Machine is 19.97%, Cutting

Machine is 57.54%, Grinding Machine is 71.87%, Coating is 46.92%, Inspection and

Packaging is 98.16%.
 Automated Die Caster average utilization rate is 25.23%, Cutter is 7.36%,

Grinder is 59.89%, Coater is 55.50%, Packager is 4.28%, Repairman is 2.55%, Mover 1

is 4.59%, and Mover 2 is 9.79%.

Automated Die Caster average utilization rate is 74.77%, Cutter is 23.4%, Grinder is

40.11%, Coater is 44.50%, Packager is 95.72%, Repairman is 73.45%, Mover 1 is 95.41,

and Mover 2 is 90.21%.

SUMMARY OF RESULTS:

EXISTING PROPOSED PRECRIPTIVE

Machines % % %
Number of UTILIZATI % Number of UTILIZATI % Number of UTILIZATI %
Machines ON IDLE Machines ON IDLE Machines ON IDLE
Die Casting 21.4 24.5 19.9
Machines 11 78.57% 0% 14 75.44% 6% 8 80.03% 7%
Cutting 80.7 49.5 57.5
Machines 4 19.26% 4% 5 50.45% 5% 2 42.46% 4%
Grinding 80.9 61.8 71.3
Machines 3 19.10% 0% 4 38.12% 8% 2 28.13% 7%
Coating 92.9 85.1 46.9
Machines 5 7.08% 2% 5 14.84% 6% 1 53.08% 2%
Inspection and 99.3 95.3
Packaging 4 0.63% 7% 1 4.67% 3% 1 1.84% 98%

EXISTING PROPOSED PRECRIPTIVE

Resources % % %
Number of UTILIZATI % Number of UTILIZATI % Number of UTILIZATI %
Resource ON IDLE Resource ON IDLE Resources ON IDLE
Automated Die 88.3 36.5 74.7
Caster 11 11.67% 3% 8 63.48% 2% 8 25.23% 7%
62.5 6.10 23.6
Cutter 4 37.41% 9% 4 93.90% % 2 76.36% 4%
64.8 25.4 40.1
Grinder 3 35.19% 1% 3 74.54% 6% 2 59.89% 1%
92.4 84.0 44.5
Coater 5 7.59% 1% 5 15.91% 9% 1 55.50% 0%
97.5 95.1
Packager 2 2.43% 7% 1 4.88% 2% 1 4.28% 96%
 50.8 73.4
Repairman 3 97.23% 2.77 8 49.19% 1% 8 26.55% 5%
96.5 97.1 95.4
Mover1 1 3.46% 4% 3 2.86% 4% 1 4.59% 1%
93.7 91.1 90.2
Mover2 1 6.20% 4% 3 8.86% 4% 1 9.79% 1%

OUTPUT
Plane Type
EXISTING PROPOSED PRESCRIPTIVE
Plane A 1152 2592 1872
Plane B 2016 4320 2880
Plane C 2016 5328 3600
Recommendation

-It is recommended to try all alternatives from number of resources to number of

machines to check what yields better results.

-It is also recommended to create a flow chart before the simulation.

-It is also recommended to consult an expert who has better knowledge and skills in

simulating and analyzing scenarios.

-If promodel is used for simulation it is recommended to use the latest/updated version.

Conclusion

The team suggests that the prescriptive solution must be implemented, since the

output of the model produces batch airplanes with values of A, B, and C not far from each

other and at the same time meeting the demand nearer compared with the proposed

solution. In order to increase efficiency of both resources and machines, the same

number of resources must match locations. Reducing the overall number of machines in

the facility and resources will reduce machine costs, workforce costs, and material costs.