Introduction The project includes the detailed investigation of the company named “Acme Machining”, with the vehicle disc brake as the focal point of the study. Off side (RH) and near side (LH) disc brakes are the two types of disc brakes. The main buyer from this company is Chris Car Custom Vehicle Assemble Plant…
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Current process The present procedure is one with an 8 hour shift for 20 days in a month, with both Fridays and Saturdays observed as off-days. The details of the 11 current operations being run can be seen in figure 1. Initially the present VSM or Value Stream Mapping has been developed. VSM is basically is a method to understand the dense relationship between each of the operations. It depicts time elapsed, non-conformance number, inventory and the flow of information between operations. The following advantages of VMS have been elaborated by Tapping, et al. (2002): a) Envision all of the flow of information and material used. b) Envision the relationship between operations and production control. c) Point out the waste sources in the system. d) Identify bottleneck operations. Afterwards statistical charts like bar chart, pie charts and waterfall charts are constructed. For this purpose, all the activities in the operation that that value or non-value added, must be highlighted. Value added activity is one which creates value, as customers perceive it. On the other hand, non-value activities are those, for which, the customer will not be liable to pay for. For this reason all non-value activities should be removed from the process immediately. In this scenario, cycle time is a value added activity whereas the set-up time and waiting time are tagged as non-valuable activities. Reason behind future state The immediate target of the future plan is to nullify all non-valuable activities and wastes. Waste is described as the process that does not help in cost reduction and also as a process that doesn’t add to the product value. In total, waste can be categorized in seven parts: 1. Waiting 2. Needless inventory 3. Flaws 4. Transportation 5. Overproduction 6. Incorrect processing 7. Needless motion Nevertheless, another waste which is also considered in this list as the eight waste is over-employment, which means employees, whose services are not fully utilized. This disease can only be curbed by the input of the employees in the company with innovations and better working ideas. Three major motives are involved in the consideration of lean manufacturing in the very first place. First and foremost is the expanding of the market at a global stage. Then comes, the higher demands of the customer in relation to quality and a better cost. Lastly, the old school methods are no longer accepted, for e.g. once a month delivery of the products to the customer. Lean manufacturing is an outstanding approach to achieve better operations, quality and cost wise. It is a sluggish process but contributes heavily to lessening of wastes. Additionally, it is more prone to increasing the quality of the process. The major motives behind VMS are listed and elaborated as follows: 1. TAKT time and bottleneck station TAKT is the essential element that has to be considered in lean manufacturing to meet the requirements of the customer. According to Carreiera (2005), TAKT is defined as “the frequency with which your customer consumes a unit of product”. In simple words, it can be established about TAKT time that, it is the time available for producing a product which is parallel to the needs of the customer. TAKT time can be calculated by the following formula: If the time of the process is less than the
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...? LeanManufacturing al Affiliations Introduction The leanmanufacturing company has managed to improve the efficacy in allocation indifferent ways. Lean is a production practice which are renowned for considering various expenditures of certain resources for the objectives of creating of value to their reliable customers to be somehow of a wasteful, and then targets for the elimination. Generally, Lean helps in preserving values with a reduced amount of work. The Leanmanufacturing company was firstly derived from Toyota Production Company (TPC), and in 1990s, it was then identified as...
...22 May 2007 Esterline Technologies and LeanManufacturing Is Esterline a successful company What outcome evidence from the case supports your conclusion
The case implies that Esterline is a successful company:
Financially speaking, its revenue is increasing. Quoting from the case, "Esterline closed the year with revenues of $835 million and income from continuing operations of $51 million, compared to 2004 revenues of $614 million and income from continuing operations of $29 million." This represents a double-digit rise in revenues of 35% and 75% rise in income from continuing operation. With this strong financial performance, analysts expressed their positive outlook for Esterline Technologies:...
...S.A.FEROZIE ORDER NO 164952 LEANMANUFACTURING Acme Machining Company Current Value Stream Map Legend: C=Cycle Time; S=Set-Up Time; P=Production; Sc=Waste %; W=Waiting/Idle Time.
Production Lead Time = 38.749 Days Value Added Time = 1.5 Days Wastage = 43%
MONTHLY PRODUCTION 800 SETS
DAILY PRODUCTION FIGURES
BASIS 3 SHIFTS 5 DAYS A WEEK
FUTURE STATE MAP
Acme Machining Company Future Value Stream Map
Legend: C=Cycle Time; S=Set-Up Time; P=Production; Sc=Waste %; W=Waiting/Idle Time.
Production Lead Time = 0 Days Value Added Time = 1.5 Days Wastage = 20%
MONTHLY PRODUCTION 1600 SETS
DAILY PRODUCTION FIGURES
BASIS 2 SHIFTS 5 DAYS A WEEK
Acme Machining Co. (AMC) must understand... ...
...LeanManufacturing Introduction The current paper proceeds to lend credence to the thesis that leanmanufacturing improves productivity; reduces waste; improves the morale of employees; and raises the overall profitability of a firm.
The increasing demand of consumers for the most useful products and services that has motivated industry players to find the best practice of manufacturing. Among these practices include leanmanufacturing. Compared to many other business philosophies, leanmanufacturing/operation can be one with the most advantages. It suggests business operations...
...LeanManufacturing How has Lean Methodology helped organizations in achieving their objectives and contributed to their growth? This paper draws information related to LeanManufacturing processes, tools and techniques. It traces evolution of Lean from the Toyota Production System and its expansion to the United States as ‘Lean.’ Concepts on which Lean is based, such as waste reduction and continuous improvement have been explained. A few important Lean tools and techniques have been explained in brief, with reference to their applicability. Scope of Lean applicability in different types of industries has been explained. Examples of known organizations that have successfully implemented Lean are mentioned. A brief account... of the...
...LeanManufacturing Introduction In present days, organizations are experiencing lower productivity, high costs, excessive inventory and poor workingenvironment in their production facilities. To increase the outcome while enhancing the productivity has become an increasingly tough challenge for organizations in today’s competitive business environment. This has put manufacturing processes in high stress to survive in the international competition. In manufacturing processes, there is high requirement for development of new processes, workflows and workplaces which would generate the implementation of leanmanufacturing processes in organizations. In manufacturing, the issue of cost has become one of the most significant aspects... for...
...LeanManufacturing Grade Contents Introduction 3 2. Cultural changes and Strategic HR policies 3 2 Cultural changes and possible HR solutions 3
2.2 Broad Problem Area 4
2.3 Problem definition 4
2.4 HR policies and practices 4
3. Ethical Issues and HR practices 7
3.1 Ethical Concerns 7
3.2 HR Policies to Deal with Ethical Issues 8
4. How HR can transmit cultural and fundamental changes to employees 9
4.1 Key Variables Shaping Behavior 9
4.2 HR Action 9
5. Creating a learning Organization 11
5.1 Characteristics of a Learning organization 11
6. Human Resource Aspects and Lean Revolution 11
6.1 Human Aspect of Lean 11
6.2 Human resource coordination with Lean 12
7. Conclusion 13
Organizational change... ...
...Running Head: LeanManufacturingLeanManufacturing [Institute’s Executive Summary Leanmanufacturing aims at detecting and eliminating the waste from the product process. By doing so, companies can reduce their cost, effort and time at high rate. This can be done by making a lean team and training the employees. Some famous production control systems include Toyota production system, JIT, KANBAN, production scheduling etc. Leanmanufacturing identifies seven types of wastes and work for eliminating them through a systematic process.
...LeanManufacturing--Mass Customization & Marketplace simulation due: There are steps that a company would need while in the marketplace business in order to accomplish mass customization in various customer segments. According to Cagan, & Vogel, (2002) the company should be able to know their targets in the marketing process. The company should be able to balance the efficiency of mass marketing. This means that a given company should be in a position to serve the customers or rather to take to the market exactly what the customers expect. This means that the company should have made at least a survey to their market place before supplying the product. Knowing what the clients or rather what the customers...
Lean Manufacturing is defined as removal of activities and processes that are regarded as waste so as to generate more value for customers. The target for elimination here becomes any process or activity that adds cost, consumes resources and time without creating value. Lean manufacturing implements different essential and objectives such as the Total elimination of waste, highest satisfactory of customers' needs, use of less effort with same production rate (Mehta et al.,2012).
Key lean manufacturing principles include mapping value stream, identifying value, creating the flow, seeking the perfection, and establishing pull. Lean manufacturing affects the...
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