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

Backgroun

d 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

Waste Analysis◦ Current Layout in Mississauga

Background Solution

Criteria Mississaug

a Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion

Line Balance Analysis Background Solution

Criteria Mississaug

a Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion

Background Solution

Criteria Mississauga

Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion

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 ToolWorker

Total Assigment Time (mins)

A 1.01 1.03 1.04 1.05 1.06 1.39B 1.01 1.03 1.04 1.05 1.06 1.39C 1.01 1.03 1.04 1.05 1.06 1.39D 2.01 2.03 0.75E 3.02 3.03 3.04 3.05 1.29F 3.02 3.03 3.04 3.05 1.29G 4.01 4.03 4.04 4.05 0.81H 4.01 4.03 4.04 4.05 0.81I 4.01 4.03 4.04 4.05 0.81J 5.02 5.03 5.04 5.05 0.86K 5.02 5.03 5.04 5.05 0.86L 5.02 5.03 5.04 5.05 0.86M 6.01 6.03 6.04 6.05 6.06 6.07 1.03N 6.01 6.03 6.04 6.05 6.06 6.07 1.03O 6.01 6.03 6.04 6.05 6.06 6.07 1.03P 7.01 7.03 7.04 7.05 7.06 7.07 1.54Q 7.01 7.03 7.04 7.05 7.06 7.07 1.54

Sub Tasks

Worker

A 1.01 1.03 1.04 1.05 1.06 1.39B 1.01 1.03 1.04 1.05 1.06 1.39

Sub TasksWorker

A 1.01 1.03 1.04 1.05 1.06 1.39B 1.01 1.03 1.04 1.05 1.06 1.39

Sub TasksWorker

Total Assigment Time (mins)

A 1.01 1.03 1.04 1.05 1.06 1.39B 1.01 1.03 1.04 1.05 1.06 1.39C 1.01 1.03 1.04 1.05 1.06 1.39

WorkerTotal Assigment

Time (mins)A 1.01 1.03 1.04 1.05 1.06 1.39B 1.01 1.03 1.04 1.05 1.06 1.39C 1.01 1.03 1.04 1.05 1.06 1.39

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

Output using Operational Planning Tool

Employee Assignment ToolWorker

Total Assigment Time (mins)

A 1.01 1.03 1.04 1.05 1.06 1.39B 1.01 1.03 1.04 1.05 1.06 1.39C 1.01 1.03 1.04 1.05 1.06 1.39D 2.01 2.03 0.75E 3.02 3.03 3.04 3.05 1.29F 3.02 3.03 3.04 3.05 1.29G 4.01 4.03 4.04 4.05 0.81H 4.01 4.03 4.04 4.05 0.81I 4.01 4.03 4.04 4.05 0.81J 5.02 5.03 5.04 5.05 0.86K 5.02 5.03 5.04 5.05 0.86L 5.02 5.03 5.04 5.05 0.86M 6.01 6.03 6.04 6.05 6.06 6.07 1.03N 6.01 6.03 6.04 6.05 6.06 6.07 1.03O 6.01 6.03 6.04 6.05 6.06 6.07 1.03P 7.01 7.03 7.04 7.05 7.06 7.07 1.54Q 7.01 7.03 7.04 7.05 7.06 7.07 1.54

Sub Tasks

Dynamic Line Balancing in Final Assembly

Worker

A 1.01 1.03 1.04 1.05 1.06 1.39

Q 7.01 7.03 7.04 7.05 7.06 7.07 1.54R 8.01 8.02 8.03 1.42S 8.01 8.02 8.03 1.42T 8.01 8.02 8.03 1.42U 8.03 8.04 8.05 1.58V 8.03 8.04 8.05 1.58W 8.03 8.04 8.05 1.58X 8.06 8.07 8.08 8.09 8.1 8.11 1.53Y 8.06 8.07 8.08 8.09 8.1 8.11 1.53Z 8.06 8.07 8.08 8.09 8.1 8.11 1.53

AA 8.11 8.12 8.13 8.14 8.15 1.58BB 8.11 8.12 8.13 8.14 8.15 1.58CC 8.11 8.12 8.13 8.14 8.15 1.58DD 8.15 8.16 8.17 8.18 8.19 8.2 8.21 8.22 8.23 1.31EE 8.15 8.16 8.17 8.18 8.19 8.2 8.21 8.22 8.23 1.31FF 8.15 8.16 8.17 8.18 8.19 8.2 8.21 8.22 8.23 1.31GG 8.23 8.24 8.25 8.26 8.27 1.50HH 8.23 8.24 8.25 8.26 8.27 1.50II 8.23 8.24 8.25 8.26 8.27 1.50JJ 8.27 0.83KK 8.27 0.83LL 8.27 0.83

Worker

A 1.01 1.03 1.04 1.05 1.06 1.39

Q 7.01 7.03 7.04 7.05 7.06 7.07 1.54R 8.01 8.02 8.03 1.42S 8.01 8.02 8.03 1.42T 8.01 8.02 8.03 1.42

Worker

A 1.01 1.03 1.04 1.05 1.06 1.39

Q 7.01 7.03 7.04 7.05 7.06 7.07 1.54R 8.01 8.02 8.03 1.42S 8.01 8.02 8.03 1.42T 8.01 8.02 8.03 1.42

Worker

A 1.01 1.03 1.04 1.05 1.06 1.39

T 8.01 8.02 8.03 1.42U 8.03 8.04 8.05 1.58V 8.03 8.04 8.05 1.58W 8.03 8.04 8.05 1.58

Worker

A 1.01 1.03 1.04 1.05 1.06 1.39

T 8.01 8.02 8.03 1.42U 8.03 8.04 8.05 1.58V 8.03 8.04 8.05 1.58W 8.03 8.04 8.05 1.58

SD8000 Saw

Horiz.FrameWelder(Frame

and Jamb)

SD7000 Saw

Double Miter Saw

Horiz. Sash

Welder

Frame Corner Cleaner

Sash Corner Cleaner

Table

Table

Table

Table

SD7000 Saw

SD8000 Saw

SD8000 Saw

Horiz.FrameWelder(Frame

and Jamb)

Horiz. Sash

Welder

Sash Corner Cleaner

Frame Corner Cleaner

Table

Table

Table

Table

Table

Table

Table

Table

Table

Table

Table

Table

Table

Table

Glaze

Glaze

Table

Table

Table

Table

Table

Table

Table

Table

Table

Glaze

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

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.

Sensitivity Analysis

MachineNumber of Changeove

rs

Machines Required

Number of Changeove

rs

Machines Required

SD8000 41 3 42 4Welding Frame and Jamb

29 2 30 3

SD7000 18 2 19 3Welding Sash 23 3 24 4Sash Corner Cleaner

31 2 32 3

Frame Corner Cleaner

239 2 240 3

Assumptions Background Solution

Criteria Mississauga

Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion