28-12-2015

Process flow Diagram

1 2 3
Shaping plywood Painting Attaching
panels battens

6 5 4
Gluing carpet Mounting Riveting,
hinges inserting studs

7 8
Attaching metal & Assembly of
plastic fixture L& R units

Capacity Analysis
Sr Run # of # of Workers
Batch Set up Set up Std Capacity/
No Parts time/unit shift operators shift
Size (min) time/unit time/unit week
(min)
Shaping plywood
1 3.15 2500 230 0.092 3.242 3 1 3 2260
panels
2 Painting 2.6 1500 2.6 2 2 4 3757
3 Attaching battens
Riveting,inserting
4 6.85 1000 6.85 1 1 1 356
studs
5 Mounting hinges 2.85 1500 60 0.04 2.89 1 3 3 2535
6 Gluing carpet 13 500 200 0.4 13.4 1.5 2 3 547
Attaching metal
7 22 500 0 0 22 1 10 10 1110
and plastic fixtures
9.5 19 24

Capacity not sufficient

Setup time is issues

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Some of the changes reqd

i) Use common shift pattern
ii) Operation 7 can be speeded up by reducing the cycle time , with
additional deployment of labor
iii) Operation 1 calls for additional Equipment another machine ,
to make small lot production possible
iv) Operation 4 can be speeded up with additional deployment of
labor
V) At operation 6 , set up time is very high. Additional Equipment
could be added or engineering solution to reduce the set up time
VI) A complete re-layout of the plant ,( on mixed model line basis )
to ring about a short cycle , continuous flow, single unit
production and conveyance of mixed model production

Run Time 3.15 Min 1

2.6 Min 2

6.85 Min 4
Kanban
2.85 Min 5

8.5 Min 6

22 Min 7

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Determining the Number of Kanbans

N = Number of KANBAN between workstations 7 and 8 (for Black, Tufted)
d = 6 lids per hours (assume, 48 per day as above)
L = 22 minutes = 0.36 hours (lead time at workstation 7)
S = 0.10 (6*0.36) = 0.216 (safety stock)
C = 1 Lids (Container size)

= 2.376
N= 2.376 Round up to 3 (allow some slack) or Round down to 2 (to force
improvement)

JIT Delivery (Batch Size 37, 146

per day, 732 per week )
(VOLVO) Torsland Scheduling of Vehicles
7.00 9.00 11.00 1.00 3.00

A (Wed) 37 units B (Wed) 37 units C (Wed) 37 units D (Wed) 37 units Wednesday

(VOLVO) Torsland fitting of floor lid (after 6 hr)

1.00 3.00

Wednesday A (Wed) 37 units

7.00 9.00 11.00 1.00

B (Thus) 37 units C (Thus) 37 units D (Thus) 37 units Thursday

SUNW IND Production sequence

11.00 1.00 3.00

A (Wed) B (Wed) Wednesday

37 units 37 units

7.00 9.00 11.00

C (Thus) D (Thus) Thursday

37 units 37 units