Manufacturing Line Analysis Prepared by: Veronica MacInnis, Leah Hutchison, & Carina Zorrilla
Background and Problem Solution Criteria Mississauga Facility – Current State Analysis Edmonton Facility – Future State Analysis Detailed Deliverables and Benefits Risks Conclusions
Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion Large Window Manufacturing Company Committed to producing high value products LEAN Manufacturing concepts Introducing a new window product line
Machinery Labour Window Base Pieces Optional Accessories Manufacturing Line
Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion Motion, Transportation, Waiting, Overproduction, Processing Time, Defects and Inventory Elimination of “Muda” – Waste Standardized Operations Standard Work Pull Manufacturing One-Piece Flow Facility-Consistent Layout, Sensitivity Analysis, Realistic and Adaptable Other Requirements
Waste Analysis ◦ Current Layout in Mississauga Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion
Line Balance Analysis Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion Takt Time = Available Time / Demand
Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion Greater Demand Magnify Idle Time Including Sash Demand
Redefining Available Time Time Available Machine Changeover Time = Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion Minutes per Shift Planned Employee Breaks – –
Machine Requirements Time to Produce 1 Window Adjusted Available Time ÷ = Daily Capacity of Machine Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion
Labour Requirements Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion
Operational Planning Tool Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion
Employee Assignment Tool Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion
Line Balance Analysis Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion Number of Changeovers Available Time Expected Sash Demand Expected Window Demand min 400 Units 250 Units
Output using Operational Planning Tool
Employee Assignment Tool
Dynamic Line Balancing in Final Assembly
SD8000 Saw Horiz. Frame Welder (Frame and Jamb) SD7000 Saw Double Miter Saw Horiz. Sash Welder Frame Corner Cleaner Sash Corner Cleaner Tabl e SD7000 Saw SD8000 Saw Horiz. Frame Welder (Frame and Jamb) Horiz. Sash Welder Sash Corner Cleaner Frame Corner Cleaner Tabl e Glaz e Tabl e Glaz e
Dynamic Line Balancing Sensitivity Analysis Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion
Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion Motion, Transportation, Waiting, Overproduction, Processing Time, Defects and Inventory Elimination of “Muda” – Waste Standardized Operations Standard Work Pull Manufacturing One-Piece Flow Facility-Consistent Layout, Sensitivity Analysis, Realistic and Adaptable Other Requirements
Dennis, P., & Shook, J. (2007). Lean Production Simplified. Productivity Press. McClain, J. O., Thomas, L. J., & Sox, C. (1992). "On- the-fly" line balancing with very little WIP. International Journal of Production Economics, Ohno, T. (1988). Toyota Production System: Beyond Large-Scale Production. Productivity Press. Womack, J. P., Jones, D. T., & Roos, D. (1990). The Machine that Changed the World. NewYork.
Sensitivity Analysis Machine Number of Changeovers Machines Required Number of Changeovers Machines Required SD Welding Frame and Jamb SD Welding Sash Sash Corner Cleaner Frame Corner Cleaner
Assumptions Background Solution Criteria Mississauga Analysis Edmonton Analysis Detailed Deliverables Risks Conclusion Sash Demand Employees Shared Workload