Applying factory physics to manual assembly at an aerospace fabrication site
Author(s)Konefal, Joseph G
Leaders for Global Operations Program.
Daniel E. Whitney and Yanchong (Karen) Zheng.
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The assembly of welded reservoirs at the Boeing Tube Duct, and Reservoir Center (TDRC) is a traditional batch and queue operation that relies heavily on manual craftsmanship. The production system experiences high variability in cycle times, high use of overtime, and poor ontime performance. The value provided by the system to Boeing and its customers is characterized by considering the associated costs of late delivery, inventory, labor, and opportunity cost. To understand the system's performance, the system's processes are mapped and modeled using discrete event simulation. The simulation is used to evaluate the benefits of changes to staffing, overtime implementation, and shop floor control. Based on the results of the simulation, lead times are increased to stabilize delivery and a CONWIP system is implemented to improve productivity and reduce overtime costs. Subsequent production data show that these changes are effective and that this framework provides successful strategies for value characterization, system stabilization, cost reduction, and increases in value creation.
Thesis: M.B.A., Massachusetts Institute of Technology, Sloan School of Management, in conjunction with the Leaders for Global Operations Program at MIT, 2017.Thesis: S.M. in Engineering Systems, Massachusetts Institute of Technology, School of Engineering, Institute for Data, Systems, and Society, in conjunction with the Leaders for Global Operations Program at MIT, 2017.Cataloged from PDF version of thesis.Includes bibliographical references (page 63).
DepartmentLeaders for Global Operations Program.; Massachusetts Institute of Technology. Engineering Systems Division; Massachusetts Institute of Technology. Institute for Data, Systems, and Society; Sloan School of Management
Massachusetts Institute of Technology
Sloan School of Management., Institute for Data, Systems, and Society., Engineering Systems Division., Leaders for Global Operations Program.