MAST
MAST provides the modeling system used as the base model in SAIL. MAST offers a roadmap for the transformation from a work order based production system to a production system that utilizes lean manufacturing techniques. The benefits of MAST are twofold. First, MAST provides objective analysis in finding the best solution for lean and flexible operations. The best solution includes a combination of machines, operators, inventory, and processes that work with lean manufacturing. Second, the use of MAST leads to a smooth transition from implementation to execution according to the operating plan. MAST models are exported to SAIL as the backbone for monitoring and scheduling the operation. In essence, MAST provides an easy to use modeling tool to design and plan lean manufacturing operation.
Features
- Modeling System
- Number of pallets and fixtures
- Minimum machine assignments
- Minimum tool configuration
- Layout
- Simulation
- Automated vs. manual part handling
- Labor team definition
- Buffer sizes
- Animation
- Capacity Planning
- Long term forecast demand
- Short term production mix
- Configuration of pallets, machines, and labor
- Return in investment(ROI)
Modeling System
Flow Route
Modeling begins with the flow route definition for each part/product. For factory level models, each factory process is represented as a flow center in a column of the flow route table. Each row in the table represents a product, and the process time is the sum of operation times for all of its components. Flow route generator software is used to create flow routes directly from MRP data.
Product Details
Product Details adds the production period for the study, demand quantities, kanban definitions and assignment of parts/products to kanban category. The kanban category is used to group products into families that can have continuous flow with dedicated labor and machines. Kanban size is used to study process flow from one piece to batch sizes.
Flow Center Details
A flow center represents a group of like machines or work area. The details include the number of stations in each group, setup time, and assignment of labor teams. Labor teams are used to represent flexible labor required in each flow center.
Model Details
Model details include station reliability patterns, labor team availability patterns, and specific batch schedule sequences.
Layout
The layout feature imports CAD drawings of the cell layout. Material handling sections are added to the layout for automated vehicles and manual handling. Machines and stations are located in the layout, with links to the material handling sections.
Simulation
Simulation
MAST uses an event based simulation that tracks each part through the process, all interactions between operator and machine availability, and traffic interference in automated handling systems. Statistical results are available for production rates, station use, labor use, kanban use, flow time, and vehicle use. These results reflect the integration effects resulting from the proposed operation.
Animation
Animation in MAST provides a visualization of simulated activity. Material handling vehicles move by track points, parts are located machines, stations, queues, or vehicles, and operators are located next to the station they are servicing. The motion and timing of vehicles, parts, and operators is directed from events as they occur in the simulated operation.
Cost Model
The cost model in MAST is based on an actual cost equation for annual replacement cost of machines, wage and benefit cost of labor, allocated overhead cost per year, and cost of automation. The sum of these annual costs is allocated to parts/products based on process times and efficiencies for machines and labor used in the flow route. All cost is allocated to total production in the MAST model.
Capacity Planning
Capacity
MAST capacity includes total burden hours by kanban category, burden hours by labor team, kanban quantity and flow time, and inventory vs. capacity graph. This analysis allows for the quick review of alternative kanban groupings, labor assignments, and product flow families. These alternative reviews lead to the development of Product Flows and Process Centers.
Cost Model and ROI
The cost model in MAST is based on an actual cost equation for annual replacement cost of machines, wage and benefit cost of labor, allocated overhead cost per year, and cost of automation. The sum of these annual costs is allocated to parts/products based on process times and efficiencies for machines and labor used in the flow route. All cost is allocated to total production in the MAST model.
Import/Export Model to SAIL
The model in MAST becomes the base model data used in SAIL. This "hand off" ensures that the operation is scheduled and monitored according to the engineered plan. Long term forecasts are used to reconfigure the machine assignments, number of pallets, and operators. This revised base model is exported to SAIL for use in the operation plan.