PRODUCT LAUNCH
description
Transcript of PRODUCT LAUNCH
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