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WVS is a Industrial Engineer, Mechanical Engineer, Automotive Ignition Systems Specialist, Lead Acid and Lithium Battery Consultant with world-class expertise in industrial engineering in supervisory roles, automotive ignition, lead acid battery and lithium battery products.
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- E-mail wvs@rapid-response-consulting.com
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An automotive parts manufacturer needed to double the manufacturing capacity for a particular product. The original thought was to build a second assembly line identical to the existing line for $6,000,000.
Recognizing that the facility had neither the floor space nor the capital for a new assembly line, the associate analyzed the assembly processes to determine if there was a better approach. The goal of the effort was to use "lean" techniques to optimize the costs of capital, labor and productive material and to "think" in terms of an efficient "manufacturing system". An important "tool" in the design of a manufacturing system is the "value stream map". The "value stream map" describes the manufacturing system in a visual manner. The data that is shown on a "value stream map" is typically:
- Takt time for the product (daily schedule expressed in seconds per part)
- Cycle time for each process
- Expected losses for each process
- Scrap
- Rework
- Downtime
- Model changeovers
- Staffing at each operation
By analyzing the "manufacturing system", additional staffing and equipment was needed only at three of the six processes in the assembly line. The associate changed the existing departmental layout using autocad software and proposed the changes to a team of plant personnel organized for this project. The changes to the existing assembly line were made and the benefits to the plant were:
1. substantial saving in floor space requirments
2. a capital expense of $2,100,000 instead of $6,000,000
3. an increase in productivity of 8%
Utilizing the "value stream map" and "thinking" in terms of a "manufacturing system" is not only useful for new projects but is also helpful when analyzing existing operations for constraints and cost reduction.
Read other articles by this KKAI Associate:
Cost Reduction Process Analysis
Decoupling for Increased Efficiency
| Industrial Engineer, Mechanical Engineer, Automotive Ignition Systems Specialist, Lead Acid and Lithium Battery Consultant, industrial engineering in supervisory roles, automotive ignition, lead acid battery and lithium battery products. | |
| Resume of KIF | metallurgical engineer, six sigma and lean manufacturing consultant, tps expert, pump and electronic testing equipment manufacturing specialist, quality assurance and continuous improvement consultant, failure analysis, forensic investigation and analysis, product liability expert witness testimony, engineering consulting services |
| Resume of ZXR | chemical engineer, monomer process technologist, engineering management consultant, engineering failure analysis, accident investigation, accident reconstruction, specialist, forensic analysis investigation expert, patent infringement, expert witness testimony, engineering consulting services |
| Resume of EPI | electrical engineer, power electronic systems and packaging consultant, engineering consultant, engineering failure analysis, accident investigation, accident reconstruction, specialist, forensic analysis investigation expert witness testimony, engineering consulting services |
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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
3905 Vincennes Road, Suite 320
Indianapolis, Indiana 46268
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