Posted: September 1st, 2023

Lean Production Homework essay

TASK1

Choose one of the titles “5S / Kaizen / Just in time production”. Prepare a report by examining a sample application on the subject you prefer. Please write the source (s) you benefited from under the report.

TASK2
In the same assembly line, it is desired to produce a total of 100 products, 20 from A, 30 from B and 50 from C, in 5 hours. Information on A, B, C products are given in the table below. Make the balancing of the line according to the position weight method and calculate the tasks of each station and the efficiency of the line.

Product A Product B Product C
Task No Duration (min.) Predecessor task Task No Duration (min.) Predecessor task Task No Duration (min.) Predecessor task
1 3 – 1 3 – 1 3 –
2 4 1 2 4 1 4 2 1
6 2 2 3 3 1 5 1 4
7 4 6 6 2 2,3 6 2 5
11 1 7 7 4 6 9 5 6
8 8 6 10 1 9
11 1 7,8 11 1 10

TASK3
Draw the current state value flow map for the ABC factory according to the information given below.
When you examined the current value flow map you drew, which sources of waste did you identify? Briefly explain

ABC factory manufactures various parts for cars. The “steering rod” produced in various features was chosen as the product family. The customers of this factory are the automobile manufacturer factories and after-sales service authorized services.
Due to the great variety in product configurations and the customer’s configuration requests differ from demand to demand, the steering arm is made to order. The production time of the product in ABC is 27 days. Due to the long production time and delayed orders, it takes 60 days for the product to be delivered to the customer. In addition, ABC’s customers can only make accurate predictions for two-week orders, so they make adjustments to orders 2 weeks before shipping. These order corrections require speeding up orders at the workshop.
Although the ABC production control department reports the orders to production in the order they receive from the customer, the orders are accumulated according to the product configuration to reduce the time loss in mold change. In this case, the order requires an estimation.

Product
• The steering rod is a metal rod with iron brackets welded to both ends.
• ABC’s steering rods are produced in 20 different lengths, 2 different diameters, 3 different iron bracket assemblies.

Customer requests
24000 steering bars per month
• Customer orders range from 25 to 200, the average is 50.
• Packaging is made in cardboard boxes containing a maximum of 5 pieces.
• Several times a day deliveries are made to various customers by truck.
• Each customer’s configuration request varies greatly from order to order.
• The ABC factory requests the order to be placed 60 days before delivery.
• Customers usually make changes to the order two weeks before delivery.

Production Processes
• The production steps of the factory in ABC are as shown in the figure below. The processes for the steering rod product family in ABC begin with the cutting of metal rods. Welding of iron brackets to the two ends of the rod (one end at welding1 and the other end at welding2) is followed by the process of cleaning the welding burrs by machine. Parts are painted elsewhere outside the business and then painted parts are sent to the assembly line. Iron brackets attached to both ends of the metal bar are also produced in ABC. The assembled parts are packaged and shipped to the customer daily.

• Model change between bar lengths in cutting, welding and cleaning processes is 15 minutes.
• Mold change between bar diameters in cutting, welding and cleaning processes takes 1 hour. This change takes a long time because the quality control demands are very high.
• On machines where iron brackets are processed, mold change between bracket types takes 2 hours.
• Steel bars are supplied from XYZ factory. The supply period is 16 weeks. There are two deliveries per month.
• Iron bracket raw materials are supplied from KLM factory. The supply period is 12 weeks. There are two deliveries per month.

Operation time
• There are 20 working days a month.
• Two shifts are worked in all production departments.
• Each shift is worked 8 hours, if necessary, overtime.
• There are two 15-minute breaks per shift.
• Manual operations are stopped during breaks. There is no payment for lunch.

ABC Production Control Department
• The customer receives his order 60 days in advance and enters the MRP program.
• Creates a work order for each customer, which tracks the order throughout the entire production process.
• Send work orders to production 6 weeks before shipment to run MRP for steel bar and iron bracket raw material order.
• Prepares daily priority lists for units related to production. Production unit managers order the orders in their departments according to this list.
• Receives customer changes 2 weeks before shipment and allows units to speed up those orders.
• Prepares a daily shipping schedule to the shipping department.

Process Information
1. Cutting (Performs bar cutting for various ABC products)
– Manual operation with 1 operator
– The cycle time is 15 seconds.
– Mold change time: 15 minutes for length, 1 hour for diameter.
Machine reliability 95%
Observed stock:
* 20 days of uncut bar stock before cutting and 5 days of cut bar stock

2. Welding Station 1 (assigned to this product family)
– First machined iron bracket metal bar is welded. An automated process that uses an operator to load and unload
– The cycle time is 30 seconds. (operator time 10 sec.)
– Mold change time: 15 minutes for length, 1 hour for diameter.
Machine reliability 85%
Observed stock: 3 days

3. Welding Station 2 (dedicated to this product family)
– The second machined iron bracket metal bar is welded. It is an automatic process that uses an operator for loading and unloading.
– The cycle time is 30 seconds. (operator time 10 sec.)
– Mold change time: 15 minutes for length, 1 hour for diameter.
Machine reliability 75%
Observed stock: 3 days

4. Cleaning Station (dedicated to this product family)
– Automatic process using the operator in loading and unloading
– The cycle time is 30 seconds. (operator time 10 sec.)
– Mold change time: 15 minutes for length, 1 hour for diameter.
Machine reliability 95%
Observed stock: 5 days

5. Painting (steering bar is sent out for painting process)
– Painting supply period is 2 days
– A truck will fetch the painted parts a day and take the unpainted ones.
– Observed stock: 2 days at the place where the paint was made, 6 days for the parts painted in ABC

6. Final Part Assembly (assigned to this product family)
– 6 operator manual operation
– Total processing time per part 195 sec.
– Mold change time: 10 min. Changing apparatus
Machine reliability 95%
– Observed finished product stock: 4 days

7.Iron Bracket Processing (assigned to this product family)
– Single machine automatic machining process
– The cycle time is 30 seconds.
– Mold change time: 2 hours.
Machine reliability 95%
Observed stock:
 Raw material from 20 days supplier
 4 days of machined part

8. Shipment
– Takes the parts from the finished product warehouse and prepares them for shipment by truck.

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