PRODUCT LAUNCH

25
Manufacturing Line Analysis Prepared by: Veronica MacInnis, Leah Hutchison, & Carina Zorrilla

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PRODUCT LAUNCH. Manufacturing Line Analysis Prepared by: Veronica MacInnis, Leah Hutchison, & Carina Zorrilla. Agenda. Background and Problem Solution Criteria Mississauga Facility – Current State Analysis Edmonton Facility – Future State Analysis Detailed Deliverables and Benefits Risks - PowerPoint PPT Presentation

Transcript of PRODUCT LAUNCH

Page 1: PRODUCT LAUNCH

Manufacturing Line Analysis

Prepared by: Veronica MacInnis, Leah Hutchison, & Carina Zorrilla

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Background and Problem

Solution Criteria

Mississauga Facility – Current State Analysis

Edmonton Facility – Future State Analysis

Detailed Deliverables and Benefits

Risks

Conclusions

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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

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Machinery

Labour

Window Base Pieces

Optional Accessories

Manufacturing Line

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Background Solution

Criteria Mississauga

Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion

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Waste Analysis◦ Current Layout in Mississauga

Background Solution

Criteria Mississaug

a Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion

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Line Balance Analysis Background Solution

Criteria Mississaug

a Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion

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Background Solution

Criteria Mississauga

Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion

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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 – –

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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

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Labour Requirements Background Solution

Criteria Mississauga

Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion

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Operational Planning Tool Background Solution

Criteria Mississauga

Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion

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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

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Line Balance Analysis Background Solution

Criteria Mississauga

Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion

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Output using Operational Planning Tool

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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

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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

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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

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Dynamic Line Balancing

Sensitivity Analysis

Background Solution

Criteria Mississauga

Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion

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Background Solution

Criteria Mississauga

Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion

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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.

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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

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Assumptions Background Solution

Criteria Mississauga

Analysis Edmonton

Analysis Detailed

Deliverables Risks Conclusion