Production line case study

Topics: Time, Lead time, Manufacturing Pages: 27 (2896 words) Published: February 23, 2014


Contents

Product
Annual Demand
Daily Demand1
Weekly demand2
Level 0
Level 1
Level 2

Hub 1
2,100
8.4
42

Sleeve (1)
2,100
8.4
42

Mount (4)
8,400
33.6
168

Bracket (2)
16,800
67.2
336

Bolt (2)
16,800
67.2
336
Hub 2
1700
6.8
34

Sleeve (1)
1,700
6.8
34

Mount (5)
8,500
34
170

Bracket (2)
17,000
68
340

Bolt (2)
17,000
68
340
Hub 3
2,000
8
40

Sleeve (1)
2,000
8
40

Mount (4)
8,000
32
160

Bracket (2)
16,000
64
320

Bolt (2)
16,000
64
320
Hub 4
1,500
6
30

Sleeve (1)
1,500
6
30

Mount (6)
9,000
36
180

Bracket (2)
18,000
72
360

Bolt (2)
18,000
72
360
Table : BOM including Demand per Product

Introduction
This report offers alternatives to improve the cellular manufacturing process at Spartan. The main focus of the improvements is on lead time reduction. Spartan has recently introduced cell manufacturing to improve the lead time for a family of 4 products. Although the results initially looked promising, after several weeks the performance started to decline. At the present time the lead time performance is 8 weeks. This is considered unacceptable by Spartan Management. The final target is to reach a lead time of at most 5 days, but for the short term (which is the focus for this report) the target is 15 days or less. Structure of the Report

The current chapter introduces the products and the manufacturing processes at Spartan. The next chapter, Manufacturing Cell Modeling explains in detail how the current process is simulated. The chapter Improvement Alternatives outlines the problems and improvement options that are considered for Spartan. The last chapter offers conclusions and recommendations for Spartan Management. Product and Process Information

The manufacturing cell under investigation produces Hubs. Currently the cell makes 4 different hubs. Each of these hubs consists of a hub, a number of mounts and a sleeve. The mount in turn consists of 2 brackets and 2 bolts. The BOM for each of the hubs, along with the demand is shown in Table 1. Each of the 4 hubs follows the same basic process, but the parameters of the individual machines are different. The next chapter describes the details of the process. A high level flowchart of the process is depicted below in figure 1. Each product leaves the process either as good product or as scrap.

Hub1
Equipment
Operator
Operation
Equipment
Setup (min)
Run Time (min)
Setup (min)
Run Time (min)
Bench
Bench
0
10
0
10
RfTurn
VT_Lathe
180
17
180
15
Deburr
Deburr
0
10
0
10
FnTurn
VT_Lathe
120
25.5
120
20
Inspect
Inspect
7
12
7
7
Rework
Repair
90
32
90
32
Slot
Mill
60
60
60
40
Table : Hub1 Equipment Data
Hub2
Equipment
Operator
Operation
Equipment
Setup (min)
Run Time (min)
Setup (min)
Run Time (min)
Bench
Bench
0
10
0
10
RfTurn
VT_Lathe
80
7
80
7
Deburr
Deburr
0
8
0
8
FnTurn
VT_Lathe
150
25.5
150
20
Inspect
Inspect
7
12
7
12
Rework
Repair
30
22
30
22
Tap
Drill
120
20
120
15
Table : Hub2 Equipment Data
Hub3
Equipment
Operator
Operation
Equipment
Setup (min)
Run Time (min)
Setup (min)
Run Time (min)
Bench
Bench
0
10
0
10
RfTurn
VT_Lathe
80
7
80
7
Deburr
Deburr
0
11
0
11
FnTurn
VT_Lathe
90
9.5
90
7
Inspect
Inspect
7
12
7
12
Rework
Repair
50
12
50
12
Slot
Mill
60
10
60
7
Table : Hub3 Equipment Data
Hub4
Equipment
Operator
Operation
Equipment
Setup (min)
Run Time (min)
Setup (min)
Run Time (min)
Bench
Bench
0
10
0
10
RfTurn
VT_Lathe
80
7
80
7
Deburr
Deburr
0
7
0
7
FnTurn
VT_Lathe
120
25.5
120
20
Inspect
Inspect
7
2
7
2
Rework
Repair
0
32
0
32
Tap
Drill
40
30
40
23
Table : Hub4 Equipment Data
Manufacturing Cell Modeling
This chapter delves deeper into the current situation that was introduced in the...
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