Larkfield Electronics Plant 2 — SMT and final assembly (fictional) — synthetic capacity study

{"version":1,"title":"Larkfield Electronics Plant 2 — SMT and final assembly (fictional) — synthetic capacity study","locale":"en","baselineId":"larkfield-electronics-plant-layout-a","drawingAndInventoryFloors":["G","L1","L2"],"options":[{"id":"larkfield-electronics-plant-layout-a","name":"Kitting south-west · 2 AMRs","createdAt":"2026-10-05T16:24:41.028Z","inputHash":"fnv1a-022c2bbe","spaceHash":"fnv1a-63ef2ca2","brief":{"purpose":"Synthetic operational planning example: Larkfield Electronics Plant 2 — SMT and final assembly (fictional)","decision":"Compare the stated capacity and layout changes under identical demand.","preparedFor":"Facility operations planner","sources":[{"id":"synthetic","title":"Synthetic operating brief","kind":"assumption","note":"No real site measurements, certification, demand forecast or ROI."}],"facts":[{"id":"assumption-1","label":"Operating assumption 1","value":"A fictional 84 × 48 m two-storey plant on a 100 × 64 m site, modelled from its two drawing sheets: L1 goods-in docks, 144 rack bays, kitting, four AMR chargers and dispatch; L2 four SMT lines, six test benches, two packing benches and a pallet build area.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-2","label":"Operating assumption 2","value":"One goods lift (one car, one AMR at a time, 0.6 m/s, 8 s doors, 6 s dwell) and two stairs join the floors. 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AMRs","inputHash":"fnv1a-022c2bbe","spaceHash":"fnv1a-63ef2ca2","status":"unknown","measurements":[],"fixedChanges":[],"unknowns":[],"criticalUnknowns":[],"assumptions":[{"id":"assumption-1","label":"Operating assumption 1","value":"A fictional 84 × 48 m two-storey plant on a 100 × 64 m site, modelled from its two drawing sheets: L1 goods-in docks, 144 rack bays, kitting, four AMR chargers and dispatch; L2 four SMT lines, six test benches, two packing benches and a pallet build area.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-2","label":"Operating assumption 2","value":"One goods lift (one car, one AMR at a time, 0.6 m/s, 8 s doors, 6 s dwell) and two stairs join the floors. AMRs use the lift only; people use the stairs.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-3","label":"Operating assumption 3","value":"Each line starts a batch every 10 minutes from a line-side kit store (3 kits at the start, reorder at 2): feeder setup 100–160 s with an operator, SMT run 300–420 s, then an operator carries the batch to a test bench (200–320 s), a packing bench (90–150 s) and the pallet build; every fourth batch goes down to dispatch on an AMR.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-4","label":"Operating assumption 4","value":"A kit reorder sends a kitter to a random rack bay (45–90 s), then to the staging area (60–120 s); an AMR (1.2 m/s) loads 30 s, rides the lift and unloads 30 s at the line. Lines fail about every three hours (exponential) and take 5–30 minutes to repair; three of the six operators take a 15-minute break at two hours.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-5","label":"Operating assumption 5","value":"Moving kitting beside the lift shortens every AMR trip but lengthens every kitter trip to the racks: kitter utilisation rises from about 0.54 to 0.78 with two kitters, and with one kitter the kitter, not the AMRs, limits supply in either layout.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-6","label":"Operating assumption 6","value":"Four-hour shift, seed 11, three runs. Lift cars run at constant speed without acceleration; an AMR counts as one passenger of a one-passenger car.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-7","label":"Operating assumption 7","value":"Synthetic drawings and demand. Robot traffic conflicts, charging, real dispatch rules, fire escape and costs are not calculated.","status":"assumed","sourceId":"synthetic","decisionCritical":false}]},{"id":"larkfield-electronics-plant-layout-b","name":"Kitting beside the lift · 2 AMRs","inputHash":"fnv1a-6a402a5e","spaceHash":"fnv1a-13411952","status":"unknown","measurements":[],"fixedChanges":[],"unknowns":[],"criticalUnknowns":[],"assumptions":[{"id":"assumption-1","label":"Operating assumption 1","value":"A fictional 84 × 48 m two-storey plant on a 100 × 64 m site, modelled from its two drawing sheets: L1 goods-in docks, 144 rack bays, kitting, four AMR chargers and dispatch; L2 four SMT lines, six test benches, two packing benches and a pallet build area.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-2","label":"Operating assumption 2","value":"One goods lift (one car, one AMR at a time, 0.6 m/s, 8 s doors, 6 s dwell) and two stairs join the floors. AMRs use the lift only; people use the stairs.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-3","label":"Operating assumption 3","value":"Each line starts a batch every 10 minutes from a line-side kit store (3 kits at the start, reorder at 2): feeder setup 100–160 s with an operator, SMT run 300–420 s, then an operator carries the batch to a test bench (200–320 s), a packing bench (90–150 s) and the pallet build; every fourth batch goes down to dispatch on an AMR.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-4","label":"Operating assumption 4","value":"A kit reorder sends a kitter to a random rack bay (45–90 s), then to the staging area (60–120 s); an AMR (1.2 m/s) loads 30 s, rides the lift and unloads 30 s at the line. Lines fail about every three hours (exponential) and take 5–30 minutes to repair; three of the six operators take a 15-minute break at two hours.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-5","label":"Operating assumption 5","value":"Moving kitting beside the lift shortens every AMR trip but lengthens every kitter trip to the racks: kitter utilisation rises from about 0.54 to 0.78 with two kitters, and with one kitter the kitter, not the AMRs, limits supply in either layout.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-6","label":"Operating assumption 6","value":"Four-hour shift, seed 11, three runs. Lift cars run at constant speed without acceleration; an AMR counts as one passenger of a one-passenger car.","status":"assumed","sourceId":"synthetic","decisionCritical":false},{"id":"assumption-7","label":"Operating assumption 7","value":"Synthetic drawings and demand. Robot traffic conflicts, charging, real dispatch rules, fire escape and costs are not calculated.","status":"assumed","sourceId":"synthetic","decisionCritical":false}]}],"status":"needs_confirmation","shortlist":[],"recommendation":null,"scope":"Only the supplied criteria and tested drawings. No queues, crowd physics, code compliance, real-site verification or global optimum. Assumptions remain conditional."},"costComparisons":[],"omittedCostComparisons":[]}