Business Analytics
Simul8 Workshop 3 (over 2 weeks)
Production Predictions at Braeheart eBikes
1. Introduction
The production manager at Braeheart eBikes has suggested a radical approach to the production and quality issues in the company. He has found that the raw materials for the frame can be pre-painted by the supplier with Braeheart logos. The Marketing manager has also been trying to respond to customer confusions – that there are too many models and this causes customer confusion. The CEO is looking for ideas to help smooth production and promote company growth.
2. Suggested Changes: Reducing Production Time and Increasing Quality
There are currently six models of the Braeheart eBike. Model 6 exploits the latest technology including a lightweight battery and a small powerful motor similar to that being developed by Dyson. Models 5 and 6 also have a radical feature of a removable battery and motor, converting it into a conventional good quality bicycle. This feature is especially desirable for customers with limited storage space at home and this one, convertible bicycle provides many options. Models 1 and 2 have no electric motor but there is an upgrade package that can be installed at a later date; this is relatively expensive and involves taking the bicycle to an approved Braeheart eBike engineer but this option appears to be attractive to some customers. The characteristics of each model are summarised in table 1.
Model Electric
components Mechanical components Comment
1 A Manual bicycle with basic mechanical components.
2 B Manual bicycle with advanced mechanical components.
3 A A Electric (non-convertible) bicycle with a basic electric motor and battery, and basic mechanical components.
4 B A Electric (non-convertible) bicycle with a lightweight, powerful electric motor and battery, and basic mechanical components.
5 A B Convertible bicycle with a basic electric motor and battery, and advanced mechanical components.
6 B B Convertible bicycle with a lightweight, powerful electric motor and battery, and advanced mechanical components.
Table 1 Models and options
The production manager and marketing manager combined their concerns, and have suggested that choice simplification is important for customers, and that production issues need to be simplified. Their research with customers that Braeheart suggests: 1. Dispense with models 1 and 2 (remove manual models from portfolio)
Aggregate the best features of models 3 and 4 (non-convertible bike with electric components), charge customers at level of cheaper bike
Aggregate the best features of models 5 and 6 (convertible bike with electrical components), charge customers at level of more expensive bike
Model Electric
components Mechanical components Comment
1 A B Electric (non-convertible) bicycle with a basic electric motor and battery, and advanced mechanical components.
2 B B Convertible bicycle with a lightweight, powerful electric motor and battery, and advanced mechanical components.
Table 2 Models and options
It has been found that the mechanical installation time is reduced to 50 minutes when the mechanical options are reduced. The sequence is illustrated in figure 1.
Given the high demand, staff working patterns and holidays are organised to minimise any disruption to production, working overtime if necessary. Effectively production continues for 52 weeks p.a. working Monday-Friday 0900-1700.
Figure 1 The newly proposed production process
Your Group Task
Represent this proposed production pattern in Simul8. (Notes: final quality inspection is a 6 minute process, and because the mechanical installation process has been simplified, it is found that mechanical installation will take 50 minutes).
Element 1
Calculate averaged production times and orders from the data already given in the Braeheart production data and describe how the data is important.
Element 2
Build a model in Simul8. Amalgamate orders for models 3 and 4, and models 5 and 6, using the average time for construction at each workstation to simulate the processes of assembling eBikes.
Element 3
Demonstrate, using the model, if the model can cope with a production schedule of 1200 bicycles per month.
Represent this proposed production pattern in Simul8.
