Manufacturing Engineering Management - Research Paper Example

Executive summary For the assembly lines to run effectively and efficiently all, the above mentioned resources have to work in a complex integral manner and any error or defects should be identified in its initial stages or prior to the initiation of the operation. A local body shop owner has obtained the contract to manufacture 100 buggy fuel tank units per week. The owner has to set up a new manufacturing line to produce the initial volume of units. So that the workers who work in the body shop utilized effectively on each component that is only for the tank manufacturing. After working with the buyer based on his requirements. This report has given into detailed manufacturing automotive engineering simulation process. The simulation process found that Emphasis should be on the value stream map of the products. The lean manufacturing organization to assess the period taken from the time the raw material enter the system to the last stage. The efficiency of the mechanical flow to the market supply should remain constant. All the machines should be well maintained and serviced for effective operation. Table of Contents Executive summary 1 Table of Contents 2 1.0 Introduction 2 2.0 Problem definition 4 2.1 Objectives of the Study 5 2.2 The area Coverage 5 3.0The Followed Order of Its Arrangement 6 3.1 The Principle of Lean Manufacturing 6 3.2 The Value Stream Mapping 6 3.3 Customization of Mass 6 4.1 The Process of Manufacturing 8 4.2 Simulation of Manufacturing Process: 9 5.0 Simulation results 10 5.1 Layout plan for production of 2000 fuel tanks for 1000 buggies: 11 6.0 Value streaming mapping 11 6.1 Pre-Event Work 13 6.2 The Main Event 13 6.3 The Accountability Process 14 7.0 Illustrations and summary 15 8.0 Recommendation and Conclusion 16 1.0 Introduction In the manufacturing assembly, various items need to be changed in order to get particular targeted production on the commodity supply. These include tools, commodity, human resource and all necessary for manufacturing. Effective functioning of the machines depends upon proper and efficient coordination of the tools, commodity, human resource and any other important requirements. They have to work in a coordinated system and any inconveniency identified addressed at its initial stages. The property given to a system has to be measurable and validated, for example the number of operators; given particular assembly requirements for machining are essential approaches to be considered when forecast an assembly line .The multifaceted nature of the mechanized order has called advancement in demands for simulation of the manufacturing progression. Simulation process is the use of visible world to deal with real functional aspects of a system. It provides assessment to test out plans or gain in sight to substitute manufacturing approaches to devise and produce. Considering it involves looking into the workability on successful operation of the plant to give the company advantage over fellow companies producing the same commodity. As an outcome, it is probable to discontinue superfluous expenditure of valuable resources. To see to manufacturing procurement and position control functions. Simulation software (Simul8) used in the manufacturing industry, healthcare, technology and servers to create and understand actual world systems. The software system has different applicability in the system attending to aspects from input, resources and the product exit level. The above-mentioned thoughtfulness inputs are necessary to arrive and predict initial commodity period and the exiting time of the product, the other parameters that influence the two main input and output parameters are the assembly rate of each matching, equipment failure, process time and the functioning capacity of each system. The outlaid foundations can be seen as the most important factors on the software applicability to get quick and efficient product. The automotive industry has a range of invention practices to manufacture and assemble the various apparatus. The production process and system has increased the possibility for new skills. The complete application of this process is at stages in which it affirms the requisite new motor producers manufacture requires. Therefore in this account manufacturing process are projected and laid for the manufacturing of fuel tank that can be installed into an off road buggy vehicle. 2.0 Problem definition A local entrepreneur has obtained an order to manufacture 100 buggy fuel tank units weekly. He has to put in place possible manufacturing approaches to meet the production. So the order in making good use of the labor source in the tank production level. After successful work with the customers on their requirements, the fuel tank had to have a volume capacity of 32 litters. The experts who work at the body shop identified two tans clumped at the vehicle chesses, both the two tanks can be located besides each other either each tank material capacity of two liters of fuel. The sample outward makeup of the proposed tanks looks like. Figure 1: intended viewpoint of the right and left fuel tanks The bits and pieces selected for the product was 6061-T651 Aluminum Sheet - (ASTM B209, QQ-A-250/11) offers an amalgamation of corrosion resistance, increased strength, and useful material surrendering it the most used aluminum grade. 6061 Aluminum resists cracking due to stress, it withstands the heat capacity, and it is cheap connecting element and is capable toast but limited on nature. 6061 perfect sheet for framing. The textile trait is as non-magnetic, Brinell = 95, Tensile = 45,000, Yield = 40,000 (+/-) The initial targeted production capacity by the shop owner are 200 fuel tanks per to achieve the early machine targets. The manager considers the shop to have 8 hours daily working shifts, which apply to weekday’s operation. The manager also has to improve the production layout in order to improve the production units from 200 to 2000 tanks weekly. 2.1 Objectives of the Study The set project objectives are as: i. To make manufacture buggy fuel tanks for market demand of 100units/week ii. Proposed value stream map for the intended unit’s production. iii. To advance the production outline for the making of 1000 units/week to suit market demands ­­­­­ iv. To identify some suggestions for the current manufacturing efficiency improvement 2.2 The area Coverage The focal point of this report is mainly in the fuel tank production needed for a very specific model in the off road buggy class, it’s the adoption of SIMUL 8 to produce 200 fuel tanks per day and further improvement to make up to 2000 tanks weekly. Secondly, proportions and qualities of the fuel tank system measured as shown on graphs 1 and 2. Finally, the report has some limitations resulting into academic complexity for example adopting a SIMUL8’s academic license and little considerations put on the complex manufacturing issues 3.0The Followed Order of Its Arrangement Control rate manufacture and update on the system of the operation gives the best outcome. The usage of the software is to generate the required capacity and to possible ways at the process can work to produce to meet the market requirement. 3.1 The Principle of Lean Manufacturing The idea of lean manufacturing is an adopted system of operation in the manufacturing plant. It ensures the best quality meet the demand, reduce the possible wastage and ensure the market satisfaction. The lean manufacturing is a system that the manufacturing industry adopt as a process to look into the operation that look into success of the workers and how the system work to ensure consistent market continuity and success in the manufacturing operation. 3.2 The Value Stream Mapping Lean manufacturing system uses the value stream mapping, alternatively known as “Material and Information flow mapping”. This management tool used to capitalize on used products reducing the products. This management tests the application of the lean manufacturing tool to achieve the beast product outcome and set the working system in a consistent flow. 3.3 Customization of Mass Customization of mass is the increased standard of using the available products to complete the process. The main hurdles faced by the producers on the customization is to keep cheaper price and ensure the production standardized , to achieve the best products and maintain the best commodity states on the produce keeping the supply time in mind so that the customers get the products in time when need arises. When looking at the Toyota application for the customization of mass aims at producing large commodity at any product outcome. Toyota was put in use and offer in approach where the products are brought at the customer request. The usefulness of the customization of mass is based on the principle under which: (1) To achieve the build up at a cheaper costal value. (2) To retain the general quality in mind when producing larger product units. (3) The production system has to remain on the high rate (4) That all the production system should be open and accountable to all (5) All the units and resources have to be used in the best way possible to give the required unit. 4.0 The Modeling Process The figures below, shows the dimensions of the two fuel tanks and installed on to the chassis of the truck. Optimized production enforces Lean manufacturing principle as an important aspect in this and is an effective processing tool based on Toyota’s production system (TPS).This principle majorly applied in designing manufacturing process. It focuses on improving value to the customer by plunging and eliminating wastage. In addition, it improves the overall flow of the process, which eradicates the non-value adding activities available. Fig. 2: Fuel tank dimensions 4.1 The Process of Manufacturing Fuel tank system is symmetrical in size and shape located on two sides of the buggy chassis. Simulation is setup to manufacture 200 fuel tank and quantity of sheets would be totally 40 aluminum sheets where 20 sheets are of 2mm for both sides of fuel tanks and 20 sheets of 1mm for baffle plates. This activity takes value stream map initial process and for laser cutting and twisting, sheets run through the queue equally. After the process in which top part drilled for tank hole, and the bottom part welded to muddle plates (cut & welded 1mm sheet), the top and bottom part separates. Lastly, the top and bottom part with stump plate now welded jointly. Final checking area is where the final product goes. Fig.3: Fuel Tank part-wise dimensions and views 4.2 Simulation of Manufacturing Process: The SIMUL8 student version used for the simulation process as suggested is user-friendly software. Entities taken are well defined and the installation clearly defined. For designing the layout, the tools namely starting point, queue, and activity and ending-points, are used. Entities a given to all tools when acquiring the results. Where the materials start to be in the queue is the starting point. Where materials held for the further processing is the queue in this project is the area. What is ways considered, are machines or workers executing operations. Where the work completes with certain output is the ending point. The input values given in deliberation of average distribution and proper appraisal of inter arrival timings a simulation. The production of 100 buggies produced in 5 days of a week with eight working hours each day. Proper reinforcing of the personnel and machines preserved and assigned with timings. Each shift allocated with eight working hours and roughly 15minutes for heating up in each shift. 5.0 Simulation results After carrying out simulation process, the results recorded below. For the production of 200 fuel tanks for 100 buggies, the images in the previous have the layout and the results for the layout with the demarcated limits shown. 5.1 Layout plan for production of 2000 fuel tanks for 1000 buggies: For attaining the target of making 2000 fuel tanks, cannot be possible with the production layout of making 200 fuel tanks for 100 buggies. It all needs more preset machinery and employees for its functionality. Accomplishing the target, the normal single shift per day is not appropriate. Two shifts per day with certain working hours should be available. For efficiency, the welders at the queue should be more in number and increasing the initial intake of materials if needed. 6.0 Value streaming mapping It is a special type of flow chart that uses symbols known as "the language of Lean" to depict and improve the flow of inventory and information. Value stream mapping loosely represented by a flow chart that uses symbols called the language of Lean to depict and improve the flow of inventory and information. Value stream mapping used to provide optimum value to the customer through a complete value creation process. (Bhasin 2015, p.150). Value Stream Analysis is a planning process that uses value stream maps to communicate how Information and Flow Material Flow. It provides optimum value to the customer through a complete value creation process with minimum waste in: – Design (concept to customer) – Build (order to delivery) – Sustain (in-use through life cycle to service) Three-value stream maps created are the Current state, Ideal state and Future state (Tanco, Santos, Rodriguez & Reich, 2012, p.710). Current state-manufacturing Ideal state manufacturing Future state manufacturing Ideal State-non-manufacturing Future State-non-manufacturing The Value Stream Analysis Process includes; Pre-event work Phase, Main Event Phase, and accountability Process Phase. 6.1 Pre-Event Work It occurs in weeks that is for three weeks prior to the event, involves determining team members, defining the objective of the team, selecting the area and topic, inviting team members to the event and clarifying roles and responsibilities(Bhasin 2015, p.150). Two weeks to the event involves, determining future demand, reviewing prior event data, any customer issues and any requirements for capital equipment. Finally, One week prior to the event involves, verifying customer demand and reviewing data (Tanco et al. 2012). 6.2 The Main Event It involves Training by learning the concepts of Lean need for its application, Gemba Walk that is where the process of identifying what to map. Also, value streaming map current state, developing Ideal State map, developing future state map, developing future state plan and management report out(Bhasin 2015, p.150). For current state map, map the physical flow, information flow, complete the lead-time data bar and visually identify waste as summarized (Tanco et al. 2012). 6.3 The Accountability Process The momentum for improvement is never higher. At the end of the event, one sees the waste. Accountability process must start immediately following the event and display the current state map and future state plan in the affected area. Commit in front of the maps and make a plan (Tanco et al. 2012). Plotted above is the value stream map of the product Using Microsoft Visio. It illustrates from the raw material entering into the body shop. The process starts at arrival of materials and then placed in the queue for laser cutting and proceeds to the machine. Soon the bending process ends and proceeds to welding machines or the welders for further processing. The welded bottom part and baffle plates are welded and latter brought together with top parts of fuel tanks to weld them jointly. Lastly, to maintain the expected quality of the product, the end product sent through final examination area for the strength tests and finished product stocked up in the inventory shop is obtained. 7.0 Illustrations and summary The layout given above is the final attempt and successfully conforms to the essential production. It works out after some trials and calculations in processing involved. Many resources removed from the process to perceive the lean manufacturing. For current state map, map the physical flow, information flow, complete the lead-time data bar and visually identify waste as summarized. From the trial on the service delivery and the structure, the discussion looks at the layout and gives a result that stands no further usage of the products on a trial system. Lean manufacturing success depends partly on the delivery but much on the time taken to build the necessary momentum (Hong 2015). The targeted product outcome on the near future value stream mapping should double the efficiency of the process. The journey of lean manufacturing should focus on long-term results that are it remains a journey forever. To achieve these by the use of the tools such as kaizen can provide very quick and meaningful improvement on the process. Without looking into the implementation of a program that yields sustainable benefits, the process effectiveness by the lean tools will retard the future production and quality of the market produce (Li 2015, p. 414). This process’s sustainable results through the entire production phase should improve to enable profit realization. The doubling of the company production depends upon how best the lean manufacturing will achieve the replacement of human labor (Hong 2015). The offloading serves the focal point of the assimilated product delivery efficiency. The company is to then take the initiative to educate the workers on why the adoption of the machine loading and offloading system. People will remain resistant to changes therefore as the company embarks on lean manufacturing, the company to remove the fears of what the employees could think of underperformance or poor quality products. Move forward the fearful choice of explaining to employees that lean manufacturing is not cutting off staff, but working smarter to preserve heads and expand the workforce for market growth. For the production control, the future state manufacturing should be adopted working on daily order rather than idea state manufacturing that operate on the weekly order. Those resistant to change will see the efficiency of production rather than work substitution. 8.0 Recommendation and Conclusion The according to trial (Li 2015, p. 414; Hong 2015), recommendations are as follows: Organize a learning experience for all workers, since people need new skills and workshop orientation. Education and training by encouraging experiments at every process of daily lean manufacturing production Use recommended tool Kaizen. This will assist in quick gain and pay for the investments Supervising of all the departments from accounting keenly, to human resource and manufacturing. Adopt the future state manufacturing of production control on the value-streaming mapping. This phase is efficient and works on the daily production rather than weekly lean manufacturing that may delay the market flow. Continuous production should be maintained to Grade the effectiveness of learning from the long journeys attended. The experience from the roadmaps assists in learning the lean performance. Evaluates the lean phase success, in the evaluation, the company should think of their ways. By copying other companies like Toyota, one lean manufacturing firm a lean manufacturing company may not devise the approaches to the constraints and challenges. Conduct a survey to work and trace the prevailing obstacles to lean manufacturing success. Emphasize value stream map of the products. The lean manufacturing organization assess the period taken from the time the raw material enter the system to the last stage. Assess the period taken from the time the raw material enter the system to the last stage. The efficiency of the mechanical flow to the market supply should remain constant. All the machines should be well maintained and serviced for effective operation All the machines should be well maintained and serviced for effective operation (Hong 2015). The welding machines and vendors assessed daily to ease the bending process of the tanks. . References: Hong, Z., 2015. Higher Vocational Colleges' Intelligently Shared Professional Teaching Resource Library System Based on Mobile Agent. Li, L., 2015, Offline Evaluation and Optimization of Interactive Systems. In Proceedings of Eighth ACM International Conferences on Web Search and Data Mining, February. pp. 413-414. Bhasin,S., 2015. The impact of Lean. In Lean Management Beyond Manufacturing Springer International Publishing, pp. 149-160. Tanco, M., Santos, J., Rodríguez, J. L., & Reich, J.,2012. Lean toolbox seasonal process industries: A nougat fabrication case study. In 6th International Conference on Industrial Engineering and Industrial Management, July. pp. 707-71 http://www.metalsdepot.com/products/alum2.phtml?page=sheet. Week 6 lecture notes, Jason Miller, 2014. Week 5 lecture Notes, Jason Miller, 2014. Read More

Figure 1: intended viewpoint of the right and left fuel tanks The bits and pieces selected for the product was 6061-T651 Aluminum Sheet - (ASTM B209, QQ-A-250/11) offers an amalgamation of corrosion resistance, increased strength, and useful material surrendering it the most used aluminum grade. 6061 Aluminum resists cracking due to stress, it withstands the heat capacity, and it is cheap connecting element and is capable toast but limited on nature. 6061 perfect sheet for framing. The textile trait is as non-magnetic, Brinell = 95, Tensile = 45,000, Yield = 40,000 (+/-) The initial targeted production capacity by the shop owner are 200 fuel tanks per to achieve the early machine targets.

The manager considers the shop to have 8 hours daily working shifts, which apply to weekday’s operation. The manager also has to improve the production layout in order to improve the production units from 200 to 2000 tanks weekly. 2.1 Objectives of the Study The set project objectives are as: i. To make manufacture buggy fuel tanks for market demand of 100units/week ii. Proposed value stream map for the intended unit’s production. iii. To advance the production outline for the making of 1000 units/week to suit market demands ­­­­­ iv.

To identify some suggestions for the current manufacturing efficiency improvement 2.2 The area Coverage The focal point of this report is mainly in the fuel tank production needed for a very specific model in the off road buggy class, it’s the adoption of SIMUL 8 to produce 200 fuel tanks per day and further improvement to make up to 2000 tanks weekly. Secondly, proportions and qualities of the fuel tank system measured as shown on graphs 1 and 2. Finally, the report has some limitations resulting into academic complexity for example adopting a SIMUL8’s academic license and little considerations put on the complex manufacturing issues 3.

0The Followed Order of Its Arrangement Control rate manufacture and update on the system of the operation gives the best outcome. The usage of the software is to generate the required capacity and to possible ways at the process can work to produce to meet the market requirement. 3.1 The Principle of Lean Manufacturing The idea of lean manufacturing is an adopted system of operation in the manufacturing plant. It ensures the best quality meet the demand, reduce the possible wastage and ensure the market satisfaction.

The lean manufacturing is a system that the manufacturing industry adopt as a process to look into the operation that look into success of the workers and how the system work to ensure consistent market continuity and success in the manufacturing operation. 3.2 The Value Stream Mapping Lean manufacturing system uses the value stream mapping, alternatively known as “Material and Information flow mapping”. This management tool used to capitalize on used products reducing the products. This management tests the application of the lean manufacturing tool to achieve the beast product outcome and set the working system in a consistent flow. 3.3 Customization of Mass Customization of mass is the increased standard of using the available products to complete the process.

The main hurdles faced by the producers on the customization is to keep cheaper price and ensure the production standardized , to achieve the best products and maintain the best commodity states on the produce keeping the supply time in mind so that the customers get the products in time when need arises. When looking at the Toyota application for the customization of mass aims at producing large commodity at any product outcome. Toyota was put in use and offer in approach where the products are brought at the customer request.

The usefulness of the customization of mass is based on the principle under which: (1) To achieve the build up at a cheaper costal value. (2) To retain the general quality in mind when producing larger product units. (3) The production system has to remain on the high rate (4) That all the production system should be open and accountable to all (5) All the units and resources have to be used in the best way possible to give the required unit. 4.

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