代写6040MAA Manufacturing Process Improvement代写留学生Matlab语言程序
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6040MAA
Improving the Manufactring process at Arrow Industries
Assignment Task
Arrow Industries is a manufacturing company of tractor components for OEMs. Over the last two years Arrow industries have lost two of their major orders to overseas competitors. In an attempt to improve the manufacturing performance to be able to continue in a competitive environment, the company has employed you, as an expert in Lean principles, to turn around their manufacturing performance.
Production Processes
An initial analysis of the production data identified that the Tubular manufacturing area is one of the more profitable areas of the company, in particular the product family that contains the two parts, TB115 and TB116 which are high value, high volume, and runner products.
Arrow industries is currently producing to mass production principles. The machines have a functional layout (Figure 1) and produce parts in large batches. All moves within the same section are done manually, using trolleys.
The key manufacturing processes include sawing, turning (lathe work: lathe 1 and lathe 2), milling, painting through to assembly and packing.
The painting process is perform. in a separate building in batches of 500.
Figure 1. Current facility layout plan
Customer Requirements
· 12,500 tubes per month
o 5,700 TB115
o 6,800 TB116
· Products are delivered every day to the customer by lorry.
Work Time
· 20 working days in a month
· Operating a 3 shift system in all production operations
· 6am-2pm, 2pm-10pm, 10pm-6am
· 30 mins lunch and two 15 min breaks per shift
Production Control information
Supplier Brooks ltd provides the metal raw material on weekly bases. Every Wednesday morning, MRP system at Arrow industries sent a notification to Brooks ltd for the requirements of raw material from the approaching week. Brooks ltd deliver straight to Arrow industries on Friday.
Weekly schedule are generate by the MRP system and each department receives a weekly instruction by email. Daily shipment is required by customer.
PROCESS INFORMATION
The processes to produce the tubes TB115 and TB116 occur in the following order:
|
Processes |
Cycle Time (secs) |
Change Over time (mins) |
Process Availability |
Quality Pass rate |
|
Saw (shared resource ) EPE 2 weeks |
55 |
1.5 |
97% |
99% |
|
Lathe 1 |
150 |
11 |
84% |
94% |
|
Lathe 2 |
130 |
2 |
95% |
85% |
|
Mill |
82 |
1.1 |
90% |
95% |
|
Painting (in a separate building) |
1200 (20 mins) |
15 |
95% |
95% |
|
Assy Carrier & Inner |
68 |
None |
100% |
95% |
|
Final Assembly |
175 |
None |
95% |
83% |
|
Packing |
75 |
None |
100% |
98% |
WIP (Inventory)
· The raw material before the first process ( Saw) it is estimated to stay 5 days (waiting ) before passing to their respective processes.
· The observed WIP inventory after each process are:
|
Processes |
WIP |
|
Saw |
1,500 TB115 1,100 TB116 |
|
Lathe 1 |
600 TB115 750 TB11 |
|
Lathe 2 |
400 TB115 850 TB116 |
|
Mill |
1200 TB115 1350 TB116 |
|
Painting (in a separate building) |
790 TB115 640 TB116 |
|
Assy Carrier & Inner |
360 TB115 370 TB116 |
|
Final Assembly |
590 TB115 450 TB116 |
|
Packing |
820 TB115 630 TB116 |
· Due to the transportation required before and after the painting process there are two extra WIP inventories: One before the painting process and another one before the Assembly of the carrier and inner as follows:
o Before Painting: 900 TB115
1,200 TB116
o Before Assembly Carrier and Inner : 940 TB115
750 TB116
Despatch Department
The observed inventory of finish goods observed ready to be sent to customers is:
4,200 TB115
3,800 TB116.
Assignment tasks and marks distribution:
1. Using the data provided develop the current state map for manufacturing facility.
(15 marks)
2. Calculate the timeline, lead times, Takt time and VA ratio.
(30 marks)
3. Using the information provided and lean tools knowledge, critically appraise the current state of Arrow Industries, this should include Future state map with new recommendations.
(45 marks)
4. Report structure, presentation style. and neatness.
(10 marks)
· Design and optimize the current production process that meets customer requirements.
· Appraise the manufacturability of the component based on both technical & process compliance assisted by virtual tools.
The report to include and identified individual student contribution (2000 – 2500 words).
Submission Instructions:
You will submit the assignment on or before the due date. The submission must be in Microsoft Word, other file types will not be marked, please submit on link on turn it in. If you are graded as a pass on any of your submission attempts you will have completed the Core assessment part of this module.
Development of Skills and Attributes:
· Act with integrity
o Have awareness of how to act in a professional environment
o Take pride in my work and my achievements, leading by example
· Adapt my approach
o am resilient with the ability to self-reflect and react positively to change, challenging situations, or areas of uncertainty
· Think Creatively
o want to continue learning, recognising that personal development is ongoing and life-long.
· Communicate effectively
o Collaborate and work with other well
o Have awareness and appreciation and respect for diversity of background culture and thought