International Game Technology – Stands Manufacturing Cell

The Customer:

International Game Technology (www.IGT.com) is a global company specializing in the design, development, manufacturing, distribution and sales of computerized gaming machines and systems products. IGT is based in Reno, Nevada is one of the largest manufacturers of slot machines, employing approximately 5,000 people world wide and producing more than 120,000 machines per year.

The Challenge:

As part of implementing lean manufacturing principles, Diego Montoya M.S., Industrial Engineer at IGT, required increased production capacity while reducing space requirements and increasing existing equipment utilization. The goal was to convert their stand operations from batch to continuous flow processes. Montoya required a tool that would allow him to simulate and optimize his process designs before implementation.

The Approach:

IGT used Flexsim simulation software to build 3D simulation models of the proposed manufacturing cell configurations and analyze process cycle times, operator travel distance, tool allocation and machine failure effects in order to estimate actual system throughput. Statistical variances and multiple operator rotation schedules were also tested.

The Result:

The new manufacturing cell design occupied 50% less space as compared to the original batch process and produced 55% more output. The Flexsim model allowed for the reduction of buffer quantities to 42% with confidence, thus condensing manufacturing lead time from 1.2 days to 2.5 hours.

“Without Flexsim’s 3D animation we never would have foreseen the interaction of operators and shift rotations, as well as the implications of the proposed manufacturing cell layouts” says Montoya. “Flexsim has given both management and operators a greater understanding of our process”. IGT uses Flexsim simulation software as part of its ongoing continuous improvement process.