Automotive Production Line - Engineering Management Project - Speech or Presentation Example

Running head: Automotive Production line Engineering Management Project Submitted to: Program Coordinator: BY: Table of Contents Introduction 3 Process model setup 4 Simulation Results 6 References 14 Introduction Simio software is a tool that is used in designing a country production line of a product. The design of a production line layout for chassis fabrication will help off road buggies producer schedule process and design the chassis in a more easer way. The chassis fabrication is more of an assembly system which requires a model that will show clearly how welding, drilling and joining is done. The model simulated using Simio software will focus on effect of batch sizes, effect of time of production and other bottlenecks which will affect resource allocation and utilization. The model simulated will be able to trace the department either welding or jointly that is idle or the resource that is not perfectly utilized. The main aim of this is to simulate a sub-assembly of fast-growing buggies manufacturing company .the sub-assembly that will be simulated will be chassis fabrication. The main aim is to determine whether the company will be able to increase production in case of demand per week; therefore the production line will be measuring capacity and capability of production of the company. The projected demand is estimated as shown below; The demand projection for the years 2015 to 2017 year 2015 2016 2017 Quantity /year 4800 48000 96000 Quantity/month 400 4000 8000 Quantity/week 100 1000 2000 In order to model this production, a resource to achieve the above production of chassis needs to be agreed upon. This will ensure that accuracy is achieved in the result. Problem definition The objectives of this report are to focus on the opportunity to improve current production of off-road buggies through available information and establish a production line model. In the report material cutting, welding and drilling parameters are observed and considered as constant parameters in designing the model. Lower chassis frame is set up using a large fabrication squire, passion and squire up the rear roll bar, take the roll bar in passion on the lower frame. Make the heights of the top frame on the rear roll bar and lower the upper chassis frame into poison. Position the front roll bar on the top of the settings of the cross member, measure the distance between the top of each roll bar and take it into position. The pre-made top roll bar tubes can be used and tucked into position as a distance piece. The system requires various input materials time for fabrication and welding. The following shows the number of materials, machines and processing. Process model setup In order to be able to build and simulate a product line for chassis fabrication various steps are necessary. The first step requires the enumeration of assumptions which will guide how the model will work. In simulation the following assumption will be taken into consideration; There is no expected machine breakdown, maintained activities and there will be no defects. Materials will be handled manually by operators. The production line designed is a single product line where by chassis uprights will be made from 20 by 20 by 1.6RHS Product work in progress as well as buffer will be in a continuous supply. Each operator will be assigned specific duty The simulation created had locations which consisted of work in progress, working machines and processing tables. The entities for the product line included raw materials and work in progress. Simulation included the creation of arrival preteens for materials and working progress to various resources. The processing of materials had different points was also highlighted before simulation done. Welding of the component is done continually for 3 hours, drilling is done in 2 hours and cutting is done in 3.2 hours. The material that is used is 18mm of chip board. In chassis fabrication materials will be cut after marking using a chalk and protector level. an hacksaw is use to cut the sheet frame that is used to make the lower part of the chassis frame of 40 by 40 by2 RHS this is fabricated together by another frame of 30 by 30RHS for the front. Once it is fitted welding is done. Welding id done as a jointly exercise for the upper and lower chassis frames. When cutting speed increases the effect on crater wear where weakens the mechanics of tool wedge rake angle and flank wear will gradually increase with cutting speed increases and cause some critical value like VB to exceed from (0.5-0.6mm). When the tool wear reached the initial life as explained by, the tool subjected to re-sharpen and replace with new one. In this region, the tool wear become worse when the critical forces increases and subjected to tool wear out. At this region, the flank wear will be affected and reduce the cutting performances. To understand further on tool life prediction, many researchers found the tool life can be modeled and predicted by optimizing drilling parameters. The functional Taylor model were adopted such as cutting speed, feed time and thrust force for cutting operation for input variables. They suggested the modified regression analysis is useful to estimate the tool wear against to actual and based on statistical analysis by relating to the hole size being drill. The automated production control is not really possible without a means for tool wear monitoring. The study related on vibration and torque method to predict the life which discusses in unmanned production control by feasible tool wear management model to avoid delamination. Three level factorial design were tested the effects of cutting condition, the result obtained on thrust force, Torque, and tool wear. The thrust force drastically increased with cutting speed, which cause tool wear out. Tool wears mechanism and effect input were discussed where tool wear caused serious damage such as hole delamination or fiber push out. The fluctuating load acting on the cutting edge leads to completely different wear characteristics of drill bits. Simulation Results The following figure shows a production line that efficiently utilizes resources to produce chassis for 100 buggies per week. Figure 1: Model for 100 pieces When simulating the above model machine and manpower utilization was 95% and 70.9% respectively, this is shown in the percentage utilization screenshot. This is done after considering an 8 hour working day and 5 hours a week, the machines provided and manpower were under utilized by 30%. Figure 2: Model for 1000 pieces It was noted that even if the production is increased still idle time will be in existence. However the production of 1000 units will need an extra input in terms of resources. Figure 3: Efficiency and idle The targeted result was reached for the product by increasing resources and time. Welding shaping and finishing did not require many materials but required labor. Information can make or break the operations of chassis. Better methods of information formulation and presentation and typical job practices that are consistent to buggies manufacture. This may also inspire the formation of a uniform operating rate, previously a vital value that aides repair operations of buggies. Keeping the staff that encounter with customers well informed is imperative, especially in maintenance stores where buggies move at low pace and no official assembly line improves rhythm and restraint. The marks also indicate where any necessary equipment will be put, and employees will be required to be. Performance-management agencies near the plane often communicate the condition of each job; hence help the workers utilize resources more efficiently and opportunely. Employees use these detailed visual means of communication engraved on the boards to furnish the entire team, to deliver information on processes within a shorter time. Visual card displays enable technicians to view the speed at which the job should be executed and begin the work procedurally in line with the turnaround process. This system enables the team to visually assess the remaining time to complete a given task and how to improve the operations. Although, these challenges may be complex to buggies maintenance, they often come with immense opportunities and hidden gains, which revolve around the likelihood of unbeaten lean executives to attain truly distinctive expenditure and quality systems. The operations and maintenance at a number of units has indicated that buggies maker can concurrently realize cost effectiveness and high quality while constantly improving their operations in both instances. Lean approaches, employed improve quality. Owing to the significance of lean techniques, which help to eliminate unnecessary expenditure, they also avert the nonstandardized schedules of time, variable composition of working teams, and vastly asynchronous work environments that most operators now perceive to be inescapable. These places play the role of factory in which important policies and practicalities are made or revised and displays high level of waste and unpredictability. In scheduling that implement lean techniques experience challenges, such as reining in senior executives to be devoted to the effort, establishing the talent pool to spearhead it, and shunning tentative approach to lean employees, which eventually fails to tackle the genesis of problems. Still, precisely owing to the challenges that are brought about by lean team, the gains earned from the buggies that stick to the strategy could possibly be more differentiating and consistent than the fruits of more imitable strategies, such as extorting wage allowances or limiting service. Despite the strict cost-cutting measures of the airline companies, they still retain large levels of what lean researchers refer to as misuse of resources: things that don’t benefit end customers. Notably, how aircraft is used can result to waste. Other wastes may come from other internal networks of operations. This problem can be attributed to empty gates, preventable tarmac interruptions, and idle aircrafts. Unknown to many, engines worth tens of millions of dollars languish on five-week journeys via overhaul lines; some undergo from disordered layouts. Value stream analysis The value streams map below shows the process which the materials flows during the times of chassis assembly. From the value stream map above, it can be noted that materials passes three processes taking a total time of a day before it is completed as a complete chassis this is time taken between delivery from store to cutting, shaping, welding and finishing. However it can be noted that, the lead time changes regularly as shown. In the production line, chassis fabrication at any workstation is prompted by the need of workstation’s output at the following workstation. Demand triggers each step of the production process, starting with customer demand for a finished product at the end of the process and working all the way back to the demand for the direct materials at the beginning for the process, in this way, demand pull an order through the production line. The demand pulls feature of above production system achieves close coordination among workstations. The main problem of this production line is that, one process in the value stream fails will lead to fairer of enters system. Conclusion and recommendation The main aim was to develop a model of the production line to achieve productivity of 100 units which can be increased to 1000 units per week efficiently. Each buggy required 2 chassis therefore the system modeling performed to estimate the capacity and capability of the production line to produce enough chassis for production. During the analysis the set up indentified was not able to meet demand therefore there was need to improve the current set up of the production line. The improved set up was able to produce a 1000 unit per week. The models used consider processing times, rate of production and utilization of resources. The production line simulation showed that it is easer to expand product production and meet demand of the buggies. Simulation indicated how utilization of resources reduced idle time of machines and operators. References Miller, J. (2013). Lecture notes, Management of Automotive Manufacturing Engineering Process. Melbourne, Victoria, Australia: RMIT. Qayyum, A, and K.Dalgomo. 2012. Improving manufacturing systems through use of simulation. Technical Report, school of mechanical and system engineering, Newcastle University Newcastle. Tahar R. & Asghar J.Adham, 2010. Design and Analysis of Automobiles Manufacturing System Based on Simulation Model, Modern Applied Science Tjahjono, B. & Fernández, R. 2008). Practical Approach To Experimentation In A Simulation Study. Proceedings of the 2008 Winter Simulation Conference. Read More