Case 1 Economic at Buick-D-2023-v9 (5)

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EECS 352: Eng. Economics Term Project Case Study Professor Malakooti EECS 352 – Engineering Economics and Decision Analysis A-17- Revised 11/1/23-Type D Professor Malakooti Case Study Term Project General Instructions (25% of Total Grade) Submit Word-file to Canvas with Embedded Excel Objects This project must be done by each student. Any copying from any other source will result in getting an F in this course and other severe penalties. Please respond to all questions. The Report for Each Model and Each Question of the Case Study It is important to write a good report, in particular state your problem very clearly and give a brief background and rational of the problem. Describe the development of your model/solution step-by-step, along with any assumption you make. Display the results in suitable forms and discuss your analysis of results along with your conclusions and recommendations. Answer the questions posed and follow the hints and suggestions given. The final report should be prepared promptly. It should consist of the following sections and details:  Introduction---provide a brief background of the case, and present a crisp problem statement and the objective of the study—what questions you are trying to answer? For what purpose? And so on.  A. Solution Strategy from Engineering Economics point of view:—describe the approach you are using to carry out and organize your study and the assumptions you are making (make these very clear). You will most likely develop/adopt a cash flow model—show in some reasonable detail how the individual cash flows are generated and integrated.  B. Solution Strategy from Decision Making and Risk point of view:—describe the approach you are using to carry out and organize your study and the assumptions you are making (make these very clear). You will most likely develop/adopt at least two decision scenarios (alternatives) where each alternative will have at least two criteria and incorporates risk analysis. You may need to assume some information (data) for Part B.  Results—Include all EXCEL printouts in the appendix but do a good summary analysis of your computer results in this section. Please use hide rows, or hide column (to hide the middle part of a long and large sheet), or “fit-in-one-page” feature to print one sheet in one page.),  Conclusion and recommendations—take your computer results one step further by making relevant interpretation of those results o to answer the study questions that you pose in the introduction section and o to try to fully accomplish your study objective. 1

EECS 352: Eng. Economics Term Project Case Study Professor Malakooti This should include a recommendation of what choice to take and the reasoning/justification behind your recommendation.  Generate an Excel sheet for each analysis using the exact format of the template shown in the Appendix (displayed at the end of this document). The format of the report should be as following.  Introduction including the background, rational and statement of the problem  Model description: a complete detail of the mathematical model showing the decision variables, the objective function, and constraints. For each key relation, a short description should be given.  Result and Analysis: summary description of results and answer to questions including all sensitivity analysis as appropriate.  Conclusions and recommendations  Appendix A: computer outputs.  Appendix B: computer codes (if any).  Appendix C: table of coefficients (if any). Appendix D: Extra Credit (Provide Your Suggestions for Improving this Case Study; you may also provide appropriate data for your suggested questions). YouTube links . The following links should help you visualize how the Sheet Molding Compound (SMC) Process works. 1- https://www.youtube.com/watch?v=dDv0hD2ooGs 2- https://www.youtube.com/watch?v=e4Nm0jzpu7o Preview YouTube video SMC Manhole Covers-Zhejiang Resin Municipal Facility Co., 2

EECS 352: Eng. Economics Term Project Case Study Professor Malakooti Preview YouTube video Moulage Des SMC Haute pression 3

EECS 352: Eng. Economics Term Project Case Study Professor Malakooti Economic Analysis of a Modified Conveyor System at Buick-Oldsmobile-Cadillac Concepts illustrated: Payback period, present worth analysis, rate of return analysis, depreciation, and development of project cash flows. Required Readings: Text Book and Handouts of Professor Malakooti ______________________ 1. Background The Buick-Oldsmobile-Cadillac (BOC) plant in Lansing, Michigan, is involved in the fabrication and assembly of the Olds Calais, Buick Somerset Regal, and Pontiac Grand Am. A small part of the total operation is the sheet molding compound (SMC) area where plastic parts are formed from sheets of plastic material. Front-end panels (the front part of the car where the lights are housed) are produced here, and a conveyor system is used to transport the panels after they are formed. This case study examines an economic justification analysis for a proposed modification of the conveyor system that would decrease the number of workers needed while improving quality and facilitating material flow. 2. Description of Present SMC Prime and Finish Process The SMC prime and finish operation starts on the first floor with stud drivers as shown in Fig 3.1. ______________________________________________________________________ © 2001 by Chan S. Park, Department of Industrial & Systems Engineering, Auburn University - This case is developed for classroom use only. 4

EECS 352: Eng. Economics Term Project Case Study Professor Malakooti Here a machine screws a two-ended bolt into each front end panel so that it can be attached to the car later. The conveyor then moves the panels upstairs where they are washed and primed. Next, the conveyor moves the panels through an oven to heat-treat the prime coating and then returns them to the first floor. An inspector checks each panel for pits and defects and marks them for the pit filler, who uses compound to fill in the defects. The compound must dry before it is sanded (the next operation), but the current setup does not allow sufficient room for this to happen every time. After the panel is sanded down, it travels up to the second floor again, where it is inspected for any major repairs that must be made. If repairs are needed, the panel is taken of the conveyor; otherwise, it moves on to the washer, where any dust and debris is removed. The conveyor then moves the panel up to the third floor to the second prime spray booth and back down to the second floor, where it is processed through an oven. The panel is inspected again, and the pit fill and sand operations are performed as necessary. Again, the area currently allocated to this operation does not always allow the compound enough time to dry. The conveyor moves the panels to final inspection and to the packing area. Once the panels are packed, they must be moved via elevator to the first floor, where the shipping docks are located. There is only one elevator, and if it malfunctions, there is no way to transport the parts to the first floor. The existing system is producing good quality front-end panels, but the current arrangement requires that the conveyor travel frequently between three floors and separates two similar operations, requiring two supervisors. The finished and packed parts must also be moved from the second floor packing area down to the first floor with an elevator. In addition, the repair and maintenance for the conveyor system will require an estimated $180,000 in the upcoming year alone in order to keep it in operable condition. Projected maintenance costs for later years are unavailable but they are estimated to be around $100,000 per year. 3 The Proposed System The proposed system would be a modification of the current prime and finish conveyor system. It would reduce the number of trips made between floors, use just one supervisor to oversee similar operations, eliminate the need for the elevator, and reduce the number of employees needed for the prime and finish operation. The proposed system under would still be used to move the panels along a specified route while different operations are performed on them. The major change is that almost all of the major operations would be performed on the second floor as shown in Figure 3.2. The areas needed for the two pit fill and sanding operations would be located in the same general area, thus requiring only one supervisor; the result should be better control of and more uniform standards for those operations. There would be more room between the pit filling station and the sanding operation so the compound would have an adequate amount of time to dry, resulting in better quality. A sanding station for hood line sanding would be added after the stud driver machines in the proposed process. (The hood line is where the front-end panel meets the hood of the car an area very visible to the consumer.) In an effort to improve quality, it has been determined that this job should receive careful attention and be performed before the initial priming process. 5

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