Advance principle in lean manufacturing

PROD10214 Advanced Principles in Lean Manufacturing Referred/Deferred coursework 2021

Refer to the case study data (below) and:

i) Draw the current state map for the Value Stream. (30 marks)

ii) Outline the major questions which should be asked, and answered, when developing a future

state map. (20 marks)

iii) Use your answer to ii) to develop and draw a Future State Map, outlining the improvements

made by implementing a lean manufacturing strategy in this organisation. (30 marks)

iv) Produce an outline implementation plan for the transformation. (20 marks)

Case Study Data

Medway Manufacturing Ltd produces hand tools for DIYbase, a major national retailer. One particular line produces scissors in left-handed (LH) and right-handed (RH) ergonomic versions.

Production Processes

 The line’s manufacturing process involves cold-forging scissor halves from steel, grinding the blades,

assembly and packaging.

 The finished scissors are boxed and shipped to the customer’s distribution centre daily.

 50 rods of steel (raw material) are delivered by the supplier, 2 times each month.

Customer requirements

 500 pairs of scissors per day. Of which:

o 400 are right handed

o 100 are left handed

 Scissors are to be shipped on cards of 25 pairs per card.

 The customer orders in multiples of cards.

 One daily shipment is sent to the customer by truck.

Work time

 20 working days per month

 1 shift of 8 hours per day, one 1⁄2 hour break for lunch, and two 10 minute coffee breaks per day.

Production Control

 MRP system.

 Customer emails demand forecast each week to cover the next quarter year.

 Fax monthly order for raw material to supplier

 Customer emails daily firm order

 Issues weekly schedule to forging, grinding and assembly processes

 Issues daily shipping schedule to despatch Process information

The processes occur in the following sequence and each workpiece passes through all the processes.

1) Cold-forging

 Cycle time = 2 seconds

 Change-over time = 65 minutes

 Inventory in front of the process = 50 rods of raw material (equivalent to 10 days worth)

 Uptime = 90%

 1 operator

2) Grinding

 Cycle time = 40 seconds

 Change-over time = 15 minutes

 Inventory in front of process = 4000 RH sets, 1000 LH sets


 Uptime = 85%

 1 operator

3) Assembly

 Cycle time = 56 seconds

 Change-over time = 10 minutes

 Inventory in front of process = 3200 RH sets, 800 LH sets

 Uptime = 100%

 2 operators

4) Packaging

 Cycle time = 2 minutes per card

 Changeover time = 30 seconds

 Inventory in front of process = 2000 RH pairs, 500 LH pairs

 Uptime = 100%

 1 operator

5) Shipping

 One shipment per day, typically of 20 cards

 Inventory before shipping = 480 cards of RH pairs, 120 cards of LH pairs

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