1. Manufacturing Line Analysis Prepared by: Veronica MacInnis, Leah Hutchison, & Carina Zorrilla

2.  Background and Problem  Solution Criteria  Mississauga Facility – Current State Analysis  Edmonton Facility – Future State Analysis  Detailed Deliverables and Benefits  Risks  Conclusions

3.  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

4. Machinery Labour Window Base Pieces Optional Accessories Manufacturing Line

5.  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

6.  Waste Analysis ◦ Current Layout in Mississauga  Background  Solution Criteria  Mississauga Analysis  Edmonton Analysis  Detailed Deliverables  Risks  Conclusion

7.  Line Balance Analysis  Background  Solution Criteria  Mississauga Analysis  Edmonton Analysis  Detailed Deliverables  Risks  Conclusion Takt Time = Available Time / Demand

8.  Background  Solution Criteria  Mississauga Analysis  Edmonton Analysis  Detailed Deliverables  Risks  Conclusion Greater Demand Magnify Idle Time Including Sash Demand

9.  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 – –

10.  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

11.  Labour Requirements  Background  Solution Criteria  Mississauga Analysis  Edmonton Analysis  Detailed Deliverables  Risks  Conclusion

12.  Operational Planning Tool  Background  Solution Criteria  Mississauga Analysis  Edmonton Analysis  Detailed Deliverables  Risks  Conclusion

13.  Employee Assignment Tool  Background  Solution Criteria  Mississauga Analysis  Edmonton Analysis  Detailed Deliverables  Risks  Conclusion

14.  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 10 440 min 400 Units 250 Units

15.  Output using Operational Planning Tool

16.  Employee Assignment Tool

17.  Dynamic Line Balancing in Final Assembly

19. 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

20.  Dynamic Line Balancing  Sensitivity Analysis  Background  Solution Criteria  Mississauga Analysis  Edmonton Analysis  Detailed Deliverables  Risks  Conclusion

21.  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

23.  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, 283-289.  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.

24.  Sensitivity Analysis Machine Number of Changeovers Machines Required Number of Changeovers Machines Required SD8000 413424 Welding Frame and Jamb 292303 SD7000 182193 Welding Sash 233244 Sash Corner Cleaner 312323 Frame Corner Cleaner 23922403

25.  Assumptions  Background  Solution Criteria  Mississauga Analysis  Edmonton Analysis  Detailed Deliverables  Risks  Conclusion Sash Demand Employees Shared Workload