Modeling of Reactive Maintenance Using Discrete Event Simulation

To reduce ambiguity in Ford Motor Company’s staffing policies, the Tauber team created a discrete event simulation modeling methodology that can be replicated to quantitatively assess the effects of varying the number, physical positioning, and work assignments of skilled-trade personnel within a plant.

The simulation produced a scenario that utilizes one fewer electrician per crew and is able to achieve current throughput rates with a minor increase in average electrician utilization. This scenario has the potential to save Ford Motor Company $494,000 annually within the two lines modeled.

If this modeling methodology is expanded to include the entirety of the Body Shop within the plant, it is estimated that annual savings of $2,988,000 could be achieved.

View team project summary

Student Team:

Anusuya Ramdass – Master’s Degree, Supply Chain Management

Anthony Sciuto – Master’s Degree, Industrial and Operations Engineering


Project Sponsor:

Doug Rickert – Manager, Vehicle Operations

Bob Garnham – Engineering Supervisor, Vehicle Operations


Faculty Advisors:

Matthew Plumlee – College of Engineering

Brian Talbot – Ross School of Business