An Application of Simulation and Network Analysis to Capacity Planning and Material Handling Systems at Tinker Air Force Base

We developed a large simulation model to aid reconstruction efforts after a disastrous fire at Tinker Air Force Base (TAFB). The model, developed in SLAM, facilitated the analysis and efficient design of the modular repair center (cellular type) layout that replaced the previous machine-based layout in the engine overhaul facility. It has been used extensively to determine the appropriate number of machines to place within the repair center, the stacker capacity for in-process inventory, the location of elevators for sending parts to the conveyor, and the optimal design and routing scheme for the overhead conveyor system. The new layout, as predicted by the simulation model, has proven to be quite effective. The new design has decreased material handling by 50 to 80 percent, decreased flow times, allowed better management control of part transfers, saved $4.3 million from the elimination of excess machine capacity, and saved $1.8 million from higher direct labor efficiency.