Assembly flow simulation of a radar

A discrete event simulation model has been developed to predict the assembly flow time of a new radar product. The simulation was the key tool employed to identify flow constraints. The radar, production facility, and equipment complement were designed, arranged, and selected to provide the most manufacturable assembly possible. A goal was to reduce the assembly and testing cycle time from twenty-six weeks. A computer software simulation package (SLAM 2) was utilized as the foundation for simulating the assembly flow time. FORTRAN subroutines were incorporated into the software to deal with unique flow circumstances that were not accommodated by the software. Detailed information relating to the assembly operations was provided by a team selected from the engineering, manufacturing management, inspection, and production assembly staff. The simulation verified that it would be possible to achieve the cycle time goal of six weeks. Equipment and manpower constraints were identified during the simulation process and adjusted as required to achieve the flow with a given monthly production requirement. The simulation is being maintained as a planning tool to be used to identify constraints in the event that monthly output is increased. 'What-if' studies have been conducted to identify the cost of reducing constraints caused by increases in output requirement.