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Verification of Minimum Required Number of Setup Operators in a Molding Factory

#Workforce Verification #Resin Molding Process #Number of Setup Operators #Operator Cycle Diagram #Production Planning

Purpose of this Simulation Model
Verify how many setup operators are needed in a molding factory that performs parallel multi-product production across numerous machines.
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Model Overview

  • Production Line Characteristics

110 product varieties (molded parts) are produced using 20 pieces of equipment (molding machines).

  • The production period is one month. (1.228 million molded parts are produced in one month)
  • The production process consists of only one step: the molding process.
  • When switching part numbers on the molding machines, setup work is performed (setup time: maximum 2 hours).
  • Production efficiency depends on the following:
    • Production load (product model mix and quantities to be manufactured)
    • Production planning (which equipment will produce which products, in what quantities, and when) … planned by the foreman
  • At this point, if the setup crew organization (responsibility scope and number of personnel) is inappropriate, it can lead to production delays due to operators waiting for setup work on the molding machines, or reduced labor productivity due to excessive operator waiting time.
  • Key Points

GD.findi Set up worker assignments appropriately within the simulation model.

    • Register teams in advance (team name, number of setup operators assigned to the team, team shift).
      *In GD.findi, staff belonging to the same team work the same shift.
    • Assign teams to each molding machine setup task (tooling activity).
    • If multiple staff members belong to a team, the person available at that time handles the setup task.
      If no staff are available, the setup task will not be performed until staff become available.
This allows GD.findi to evaluate whether the number of operators is appropriate simply by changing team size settings.

Modeling Screen

Floor Plan Information on Equipment Layout and Transport Routes
Process Plan Information on process sequence and cycle time
Workers Information regarding working hours, assigned teams, and number of personnel
Working Hours Information on worker shifts
Worker Assignment Information regarding worker allocation for fixed-position tasks and transport tasks

This modeling was created using GD.findi MS.

It is a no-code production simulator that performs production simulations in a digital virtual space, providing powerful support for line design and process design.

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Output Report Example

■Verification of Task Assignments for Setup Workers

We will verify whether the target production of 1,228,308 units can be achieved within 30 days by changing the number of setup workers.

First, we tried 3 to 4 workers. Production did not reach the target. We tried 5 workers. Production was completed. Next, we increased the number of workers per operating hour.

Production was only completed when we increased the number of workers to 2 for operating hour “1G”.

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