Question

In a Toothpaste manufacturing environment, there are a lot of processes involved before getting the final product. It starts with the dumping of bulk raw material like calcium carbonate, silica etc. to the Mixer. In the Mixer, all the other ingredients like Glycerin, Water, Gums, Flavor etc. get added to produce the final cream. The cream is then transferred to bulk storage tanks where is it stored and buffered. The cream then flows to packing lines for tubing and finally the product is made. Below are the Queuing systems in this process:

1) The dumping of bulk raw material is done in a system which is connected to 3 Mixer systems. So, as per requirement, the material does to any system. Hence, it is a single line and 3 server model

2) The Glycerin is stored in two tanks and they supply to 3 Mixer system. So, it is the Multiple server systems

3) Each Mixer system is connected to single storage tanks and they transfer cream to designated packing line. Hence, it is a single server system. The buffer tank is a queuing tank where cream keeps on getting collected and is consumed in packing line on first come first serve basis.

Thus, the queuing system is very much relevant in all the manufacturing processes. Queueing theory deals with the analysis of queuing systems at is a described as customers arriving for service waiting for the service if it is not immediate and if it is not immediate and if having waited for service leaving the system after being served.

For the queuing system example above:

a) In order to model and analyze the system performance, what data do you need to collect? Propose a plan for data collection (e.g., survey, sensing data, database, domain knowledge, etc.)

b) Provide an example of collected data needed for modeling the system. You do not need to present the real data. “Fake” data provided here needs to be reasonable. ​

c) Recommend the improvement or optimization of system performance.

Answer 1

1a) In order to model and analyze the system performance, the following data must be collected:

• The quantity of raw material used and the quantity of end product manufactured
• The rate of waste development
• The rate at which dumping of raw materials is performed
• The rate at which supply of glycerine to main tank is maintained
• The efficiency maintained in the packing of the final product

Data can be taken from the machine records, so as to validate the source of data for analysis. Also feedback from the system operators as well as end users can be taken to facilitate the study regarding the performance of the toothpaste manufacturing process.

b) An example of collected data needed for modelling the system can be the data collected from the mixer system:

• Rate at which dumping of raw material A is done = 1.5 l/min
• Rate at which dumping of raw material B is done = 1.2 l/ min
• Rate of rotation of the mixing system = 240 rotations per min

c) For improving the overall system performance, the management must make a note of the following:

• The influence of external as well as internal factors must be taken into consideration
• The quality of the raw material must be maintained consistently
• Raw data must be procured from validated suppliers
• The storage of the intermediate mixture must be free from any kind of adulteration
• Efforts must be taken to minimize the rate of waste formation at each step of the manufacturing process. This can be facilitated by implementing 6S and Kaizen in the plant