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PRODUCT LAUNCH

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

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PRODUCT LAUNCH

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  1. PRODUCT LAUNCH Manufacturing Line Analysis Prepared by: Veronica MacInnis, Leah Hutchison, & Carina Zorrilla

  2. Agenda • Background and Problem • Solution Criteria • Mississauga Facility – Current State Analysis • Edmonton Facility – Future State Analysis • Detailed Deliverables and Benefits • Risks • Conclusions

  3. Background and Problem • Large Window Manufacturing Company • Committed to producing high value products • LEAN Manufacturing concepts • Introducing a new window product line • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion

  4. How Do You Make a Window? Labour Machinery Window Base Pieces Optional Accessories Manufacturing Line

  5. Elimination of “Muda” – Waste Solution Criteria • Motion, Transportation, Waiting, Overproduction, Processing Time, Defects and Inventory Standard Work • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion • Standardized Operations One-Piece Flow • Pull Manufacturing Other Requirements • Facility-Consistent Layout, Sensitivity Analysis, Realistic and Adaptable

  6. Methodology and Analysis Mississauga facility • Waste Analysis • Current Layout in Mississauga • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion

  7. Takt Time = Methodology and Analysis Available Time / Demand Mississauga facility • Line Balance Analysis • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion

  8. Greater Demand Considerations edmonton facility Magnify Idle Time • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion Including Sash Demand

  9. Methodology edmonton facility • Redefining Available Time • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion = Time Available Minutes per Shift – Planned Employee Breaks – Machine Changeover Time

  10. Methodology edmonton facility • Machine Requirements • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion Adjusted Available Time ÷ Time to Produce 1 Window = Daily Capacity of Machine

  11. Methodology edmonton facility • Labour Requirements • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion

  12. Methodology edmonton facility • Operational Planning Tool • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion

  13. Methodology edmonton facility • Employee Assignment Tool • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion

  14. Number of Changeovers • 10 Analysis – Edmonton Facility Available Time • 440 min • Line Balance Analysis • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion Expected Sash Demand • 400 Units Expected Window Demand • 250 Units

  15. Analysis – Edmonton Facility • Output using Operational Planning Tool

  16. Analysis – Edmonton Facility • Employee Assignment Tool

  17. Analysis – Edmonton Facility • Dynamic Line Balancing in Final Assembly

  18. Detailed Deliverables

  19. Detailed Deliverables Horiz. Frame Welder (Frame and Jamb) Sash Corner Cleaner SD7000 Saw Horiz. Sash Welder SD8000 Saw Frame Corner Cleaner Table Table Table Table Table Table Table Table Table Glaze SD8000 Saw Table Table Table Table Table Table Table Table Table Double Miter Saw Glaze Table Table Table Table Glaze Table Table Table Table Table Frame Corner Cleaner Horiz. Frame Welder (Frame and Jamb) SD8000 Saw Horiz. Sash Welder Sash Corner Cleaner SD7000 Saw

  20. Risks • Dynamic Line Balancing • Sensitivity Analysis • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion

  21. Elimination of “Muda” – Waste Return to Solution Criteria • Motion, Transportation, Waiting, Overproduction, Processing Time, Defects and Inventory Standard Work • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion • Standardized Operations One-Piece Flow • Pull Manufacturing Other Requirements • Facility-Consistent Layout, Sensitivity Analysis, Realistic and Adaptable

  22. Questions?

  23. Bibliography • 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.

  24. Analysis – Edmonton Facility • Sensitivity Analysis

  25. Methodology edmonton facility Sash Demand Employees Shared Workload • Assumptions • Background • Solution Criteria • Mississauga Analysis • Edmonton Analysis • Detailed Deliverables • Risks • Conclusion

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