|Module Learning Outcomes Assessed:
LO3- Critically review the main approaches to achieving lean manufacturing systems.
LO4- Apply a manufacturing systems engineering design/redesign methodology to design flow lines and cells.
Feit Components Ltd is a first tier supplier to the automotive industry and also produces several components for the aftermarket sector.
Over the last two years, Feit Components have lost two of their major orders to overseas competitors. In an attempt to improve the manufacturing performance to be able to continue in a competitive environment, the company has employed you, as an expert in Lean principles, to turn around their manufacturing performance.
An initial analysis of the production data identified that the family of products X405 and X406 is one of the more profitable family of products in the company.
Feit Components Ltd is currently producing to mass production principles. The machines have a functional layout (Figure 1) and produce parts in large batches. All moves within the same section are done manually, using trolleys.
The key manufacturing processes include sawing, CNC machining, spot welding, turning (lathe 2), assembly (1st and finally), and packing.
Figure 1. Current facility layout plan
Production Control information
Midlands steel ltd provides the metal raw material on weekly bases. Every Monday morning, MRP system at Feit Components Ltd send a notification to Midlands steel ltd for the requirements of raw material for the approaching week.
Weekly schedule are generate by the MRP system and each department receives a weekly instruction by email. The manufacturing department produces orders for each process on weekly basis. Daily shipment is required by customer
The processes to produce the products X405 and X406 occur in the following order:
In the first assembly process, both products (X405 and X406) are assemble to an external part provided by supplier JGH ltd on weekly bases every Wednesday.
The observed inventory of finish goods observed ready to be sent to customers is: