Optimizing a manufacturing problem

[horowitz.esther@gmail.com]

Can you experts please provide some insights on how to solve this:

Currently, the factory have 4 production lines, 2 are used for printing and 2 are used for can manufacture. However, there is a significant time difference between the different processes, whereby 1 can is painted for every 2 cans produced. Furthermore, the printing of tin cans has a greater market demand than can manufacture.

Potential Research and Development questions that could stem from reviewing the Painting Process

Only one colour can be printed at any one given time. It takes 20 minutes to paint the tin template. The template then needs to dry in a high temperature oven for 20 minutes. Once the first colour has been applied to all of the templates, the production line needs to be stopped. The dampening and ink rollers (used for paint application) need to be removed and washed using a chemical detergent. For every five hours of dye application there is an equivalent five hours required for dye removal and cleaning, before the second colour can be applied. Therefore the company are limited in the number of prints that they can produce as their current system is too time consuming. It also means that staff are not used to their full capacity due to the lag time between the processes.

1. Can the painting process be modernised to increase the number of rollers that are used (at the
same time) during the painting process without the colour smearing?
2. Can the dyes be developed so that quality is retained, but with new characteristics enabling several dyes to be used at one time.
3. Would the developed dyes be easier to clean?
4. Can the drying process be modernised to reduce the drying time required?
5. Can a different chemical detergent be applied when cleaning the dyes that reduces the cleaning
time?
6. Can the mechanics of the machine be altered to speed up the time taken to dismantle the rollers?
Currently, the furnaces need to be left on during cleaning, leading to a large wastage of energy.
7. Can the speed of the machines be increased?

Potential Research and Development questions that could stem from reviewing the Packing Process

Most packaging is done manually and 15 people are required for this process.

1. Can the packaging process be automated to reduce the total man power required?
2. Can the storage facilities be improved to accommodate a greater number of products?

[rlima@andrew.cmu.edu]

Hi,
Your manufacturing situation seems a challenge, in face of the demand being greater than capacity and all those long operations.
I think that this forum can help you in terms of optimization of the scheduling. But it will be more difficult to get help for the questions you have posted. They are two specific, which are difficult to answer without knowing the type of machines you have or the chemistry involved. For example, it will be difficult to this group to help you on this question: "Can the mechanics of the machine be altered to speed up the time taken to dismantle the rollers?"

So, in terms of scheduling the production, currently, what tools do you use? Are you optimizing the production schedule? Have you identified mathematical models that describe your process?
A good starting point would be: http://newton.cheme.cmu.edu/interfaces/home.html

Have you studied the option of increasing the painting capacity? (Analysis in terms of capital cost, ROI, and minimization of makespan benefits)

I hope this helps.
Ricardo