Headlamps Assembly Loop for Ford Aero Headlights

1. Headlamps Assembly Loop for Ford Aero Headlights Valverde-Ventura Rene Vouravis Veerakachen

2. Current Situation • 7.2 hours of production shifts • The current production of 2892 pieces per shifts can’t meet the required production of 3002 pieces per shifts • Need changes in designs to improve the performance of the loop

3. Current Layout

4. Requirement • 3002 pieces of good parts during 7.2 hour shifts. • Minimum cost

5. Design Changes • Number of pallets • Operating procedure for Leak Test Stations • Additional Aimer

6. Number of Pallets • Find the Optimum number of Pallets • Minimum number of pallet is 44 • The Optimum number of pallet is 52 • Delivers the production of 2902 parts per shift

7. Change Operating Procedure of Leak Test Station • Originally, 3 machines in the station operate simultaneously • We modified the operating procedure that each machine in the stations works independently

8. Additional Aimer • Reduce the Blocking rate of previous station • Improve the loop performance

9. Recommendation • Changing operating procedure of the Leak Test Stations should be done first • Next, change the number of pallets to the optimum • Add the Aimer, depending on the management’s cost justification

10. Modified Layout

11. The End