...Ford Assembly Line! Word Count: 1,811 I. Image of my innovation that I was allocated The Ford Assembly Line II. The innovation Product and the Process: The ford assembly line is a manufacturing process developed by Ford, which quickened process of producing cars in the early 1900’s. The product that it first helped was the car a Ford Model T. Henry Ford and many other individual’s whom were involved in Ford, came up with the idea of the assembly line in the years between 1908 and 1915 and consequently made the assembly line famous in the following decade for mass production throughout the world. They based their idea on how a slaughterhouse was run, with a conveyer belt moving animals while they were being butchered. The process of the Ford Assembly Line is as follows parts are added to the product in this case the Ford Model T, in an organised manner (for example engine first, then hood, and then the wheels) in which creates the car in a much faster fashion than if it was done by having the car in one spot and waiting till one aspect of the car was done to do the next one. Having people ready at each individual station waiting for the next car to be moved to them too add whatever is needed from the station that they are working at. No heavy lifting done with cars being moved along. Car pieces moved throughout the factory on conveyor belts. III. The Impact of the Ford Assembly Line: A radical innovation. The impact of this innovation was huge, not only...
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...Industrial Engineering Jig Design, Assembly Line Design and Work Station Design and their Effect to Productivity Adi Saptari, Wong Soon Lai, Mohd. Rizal Salleh Faculty of Manufacturing Engineering Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, Ayer Keroh, 76100 Melaka, Malaysia ___________________________________________________________________________ Abstract This report discussed the effect of workstation design, assembly design, jig design and working posture on the assembly of plugs. Two different designs of jig (vertical and rectangular) and two sets of assembly line design (one and two operators) and two set of workstations design (sitting and standing) were studied to observe their effects to productivity. Design of Experiments 23 with two levels of each factor is used to conduct an experiment for obtaining the most productive jig and assembly line design. Two groups of workers were employed to assemble the plug in 8 different ways. Number of replication is 32 for each setting and total of electric plugs produced by each group is 256 units. The results shows that jig design have the most significant effect to the assembly time. Furthermore, the other factors: assembly design and workstation design are also show significant factors to assembly time. However, interaction combinations of two or three factors were not significant to assembly time. The most productive assembly line design which achieved the lowest assembly time is the combination of one...
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...Objectives Process design: Amazon’s Challenge Measures: Capacity, Time, and More How do we quantitatively evaluate a process? – Capacity – Time – Other? ARES: – Charging Ahead to Push Electric Cars – Latest Starbucks Buzzword: ‘Lean’ Japanese Techniques 1 Amazon in 1990’s: Delivering Books 2 Amazon’s Potential Solutions What do customers want? Inventory – Large selection – Fast delivery – Low Price Eliminate the uncertainty Print on demand/eBook Transfer/Share the uncertainty How do we deal with uncertainty ? Or why is it so difficult to deliver books to customers on time and at a low cost? Transfer the inventory to a distributor 3 Potential Solutions: Transfer the inventory to the distributor Example: In the early days of Amazon.com the company did not keep any inventory of books. 4 Potential Solutions: Transfer the inventory to the distributor Amazon’s Order – The supplier Ingram kept the books for Amazon. – Once Amazon received an order, it was transmitted to Ingram. – Ingram would ship the book directly to the consumer. Amazon’s Post Order Process 5 Ingram’s Order Ingram’s Book Inventory Ingram’s Post Order Process 6 1 Potential Solutions: Transfer the inventory to the distributor ARES Changing Ahead to Push Electric Cars What are the advantages for such an arrangement for Amazon and Ingram? – Risk pooling (less inventory is needed) What are the disadvantages...
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...I am taking the role of Niel Goodrich (VP of Manufacturing) - I am hiring you as a consultant, wanting your advice on what to do about the Process Engineering Proposal (PEP). You have now read about the PEP plan to increase capacity by 50%. You know that Long is in strong disagreement. As an analyst what is your belief about the PEP - is it the right way to go? Will it increase or decrease performance? Will it affect motivation and therefore performance? Help each other out here. The objectives of the PEP are to propose a plan for initiate the assembly process associate with the new line of LDTC radiation tubes, and reform the current assembly processes in the NTAD. The PEP has definitely positive influence on the Assembly process, which will expand capacity by 50% in the nuclear tube operations. However, some stages of the PEP underestimated the NTAR workers, and the Long's effort. As a result, it will decrease the existing Assembly worker's performance. One of the important factors of the proposal is to create process specifications for the nuclear tube operations, which Long strong disagree. Long prefers to use the production standards just as a guide for the employees. However, the PEP will rewrite and reform the process specifications on existing operations. After that, the PEP needs to enforce new standards into the work process. In addition, the proposal requires that Singer approve monitoring, evaluating, and documenting any deviations or changes. It will discourage...
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...be looking at the differences in the batch process and the assembly line process. We will also be looking at what concerns the proposed change might have in different areas of a company, such as marketing, finance, human resource, accounting, and information systems. Finally, we will put together a recommendation whether or not this firm would benefit from going to an assembly line from the batch process. An assembly-line process is when you have a line of sequencing of putting a product together. A product starts at one of the assembly lines and proceeds to the next step until it is fully assembled at the end of the line. Assembly lines are known for vehicles, refrigerators, printers, computers, and a huge assortment of mass produced products for the consumer usually by a conveyor system (Schroeder, Goldstein, & Rungtusanatham, 2011). The assembly line is very proficient but is not flexible. They are able to make the same exact product over and over. The batch flow system is described as the production of a product is lots or batches. Factories that make clothing tend to use the batch system when they are making different sizes or minor differences. Most factories have the batch workstations grouped in the same area of the factory. Batch operations use general equipment that did not specialize to make one particular piece of product. This gave it the flexibility to change to make different items (Sessoms, 2013). The assembly line will tend to use low-skilled workers...
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...Identify process flow structure: assembly line production is done as there is production of discrete parts moving from workstation to workstation at a controlled rate, following the sequence needed to build the product. When other processes are employed in a line fashion along with assembly, it is commonly referred to as a production line. Production is done in the chain department (assembly lines) and for each assembly line there is a chain inspector to make sure that no errors are made. After that the product is moved to the final checking department after cleaning through the brush. After final checking, product is moved to the packing department who do the packing size wise and as per contract. Wastes are sold to the small producers. If any problem occurs in any department then it is written on the card and sends back to the department. For correction and alteration each production line has 2 to 3 persons. Process selection: assembly process would be used. Manufacturing process flow design and its rationale and suitability for the organization: manufacturing process flow design is a method to evaluate the specific processes that raw materials, parts, and subassemblies follow as they move through the plant. The most common production management tools used in planning and designing the process flow are assembly drawings, assembly charts, route sheets and flow process charts. Gap occurred when materials are not arranged. Materials sometimes could not reach on...
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...TECHNOLOGY TO CABLE ASSEMBLY PRODUCTION LINE By Luis E. Centeno A. A Research Paper Submitted in Partial Fulfillment of the Requirements for the Master of Science Degree in Management Technology Approved: 4 Semester Credits Dr. Thomas Lacksonen Research Advisor The Graduate College University of Wisconsin-Stout May, 2002 The Graduate School University of Wisconsin-Stout Menomonie, WI 54751 ABSTRACT Centeno (Va~riter)(Last Luis (First) E (Initial) Name) APPLICATION OF DEMAND FLOW TECHNOLOGY TO CABLE ASSEMBLY PRODUCTION LINE (Title) Management Technology Dr. Thomas Lacksonen May, 2002 (Graduate Major) (Research Advisor) (Month/Year) 33 (No.of Pages) Publication Manual of the American Psychological Association (Name of Style Manual Used in this Study) D.F.T. (Demand Flow Technology) principles were applied to the cable assembly operations. The main objective is to reduce production time with the implementation of a new cable assembly line designed following Demand Flow Technology concepts. The study takes place in a manufacturing company specializing in fall protection equipment that has cable assembly operation as one of the major activities in the production of its finished goods. D.F.T. is a new business strategy based on Demand Flow Manufacturing techniques that help manufacturers to optimize the production system working in all the departments of the company. The final result was a manufacturing cell layout for the cable assemblies, Improvements...
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...Effective) Assembly and Manufacturing Source: David Stienstra (Rose-Hulman) Purpose Statement To provide an overview of Design for Manufacturing and Assembly (DFMA) techniques, which are used to minimize product cost through design and process improvements. Objectives Participants will understand: – Differences and Similarities between Design for Manufacturing and Design for Assembly – Describe how product design has a primary influence – Basic criteria for Part Minimization – Quantitative analysis of a design’s efficiency – Critique product designs for ease of assembly – The importance of involving production engineers in DFMA analysis Design for Assembly Definition: DFA is the method of design of the product for ease of assembly. ‘…Optimization of the part/system assembly’ DFA is a tool used to assist the design teams in the design of products that will transition to productions at a minimum cost, focusing on the number of parts, handling and ease of assembly. Design for Manufacturing Definition: DFM is the method of design for ease of manufacturing of the collection of parts that will form the product after assembly. ‘Optimization of the manufacturing process…’ DFA is a tool used to select the most cost effective material and process to be used in the production in the early stages of product design. Differences Design for Assembly (DFA) concerned only with reducing product assembly cost – minimizes number of assembly operations...
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...feasibility of a process engineering proposal concerning the introduction of a new line of silicon sensors and several proposed changes in the existing manufacturing process of the Silicon Sensors Assembly Room. Recommendations and alternatives regarding these two matters are also provided. Name_____________ Prof. Brendan Bannister 112 Hayden Hall Signature __________ Northeastern University Boston, MA 02115 Date______________ The business world keeps evolving rapidly, especially in the technology industry. As one of the leading producers and an early pioneer in the sensor technology industry, Arc Inc. is introducing a new line of Micro-Electromechanical System (MES) in order to not only meets customers’ new needs but also enlarges its market share. Therefore, the start-up of the assembly process required for manufacturing is critical. Meanwhile, a series of changes to improve the processes used in the current assembly of existing sensors in the Silicon Sensor Assembly Department (SSR) is necessary in order to increase profitability and efficiency of the company. First of all, we will discuss the plan for start-up of the MES assembly process. The division of the Assembly Room into three...
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...Goodparts Case A. Assembling A & B is the Process with the smallest hourly production (160/hr), there for the maximum weekly production would be (5*8*160 = 6400 components produced per week) B. Because the drilling process is only occurring 8 hours a day and with 4 machines, the maximum amount of part c that can be drilled in one day is 1920 or (8*240). Assemble line 1 and the final assembly can produce 2560 (320 * 8) and 2880 (360 * 8) respectively. There will not be enough drilled part C for assembly line 1 and the final assembly to run at full efficiency. Therefore, the daily production will be limited to 1920 or 9600 per week. Based on this, the drilling operation limits the capacity. C. Assembly line 1: 2560/day or (160*16) Part C drilling: 2400/day or (60*5*8) Final assembly 2160/day or (180*12) Since the final assembly operation can only produce a maximum of 2160 a day, the maximum weekly capacity would be 10800 or (2160*5). Based on this, the final assembly operation limits the weekly capacity. D. From question B Part A: 9600 * .55 = 5280 Part B: 9600 * .45 = 4320 Part C: 9600 * .35 = 3360 Assembly 1: 9600 * .4 = 3840 Drilling: 9600 * .25 = 2400 Fin Assembly: 9600 * .4 = 3840 Cost of Elec: 9600 * .01 = 96 Over head: 3100 Depreciation: 75 Total Costs: 26311 Div: Parts Assembled 9600 Cost per unit:...
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...Time Study / Work Sampling “Lab” Report Objective 1. To perform a time and motion data analysis of an assembly task and compute the mean and standard deviation of the times recorded. 2. To discuss and analyze the set of data from (1), analyze current method, and figure out possible approaches to simplify the job and improve overall productivity. 3. To analyze the activity-time study for the secretary and compute % of time spent on each activity using different methods. 4. To develop learning curve for a jigsaw puzzle activity. Introduction This lab focuses on the study of time study, work sampling, and the learning curve. The three studies can be used to analyze the performance of a production system, thus giving adequate background to improve the system, make planning and scheduling to minimize cost, and increase safety. Time Study In this lab, Time Study data was obtained by measuring the time it takes for a pretend assembly worker to finish a task which consists of four elements. Time was taken by using a stopwatch in two different manners: running time and stop time. In running time, the process time was measured without resetting the time in between elements. In stop time, the process time was measured as individual time taken to complete one element. In this case the stop watch was stopped and reset after the completion of each element. Afterwards the data was analyzed and an evaluation on the current performance and suggestions for improvements...
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...synchronized with the core processes of the scope of the project which include the schedule, cost, facilities, team and risk management. The quality program should guide each process to ensure that the customer’s demands are able to be met. This will ensure that all of the processes are goal oriented to the customer’s needs. The process that the VW Mexico Team utilized was to develop a work breakdown structure (WBS). This structure integrated the plans submitted by various project participants and detailed the timeline for the overall project. As a quality control individual I would utilize the WBS as a structure to integrate a quality control program that would be based on Volkswagen’s expectations of it’s component assembly for the new Jetta. This program that is developed for the project will begin with obtaining information of the quality policy and procedures, customer expectations, the project scope statement and the WBS. As the case study explains, the project that VW Mexico is undertaking is to produce several motor and axle parts and assemblies that include the front axles and cornermodule assemblies. During the scope of this project, the WBS was developed and provided the detailed timeline for the overall project. The quality program will include specifications of targets for the parts and assemblies. It will also address tolerances or allowable variations for these as well. These specifications and variations must be formally addressed and approved to ensure that...
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...Introduction Just In Time (JIT) This is Toyota’s production strategy that strives to improve a business return by reducing the in process inventory, improving quality and stream lining the processes to reduce carrying costs. To meet JIT the process relies on a signal or Kanban. This signal tells production when to make a certain part or when to sequence a certain part that is required. JIT in time focuses on continuous improvement (Kaizen) and if implemented correctly can make the business very efficient with improved quality and returns on investment. Quality Assurance (QA) This is a process centred approach to ensure that Toyota is providing the best possible products or services. It is related to quality control, which focuses on the end result. Quality assurance focuses on the process to achieve the end result. Toyota uses a system called the QA Network, this acts like a net to catch defects before the end result. Toyota implements a 200% quality check by the production and stores processes even before the vehicle is sent for quality inspection. This ensures that every vehicle is fitted with the correct part in the correct way. Toyota’s QA Network is very effective in achieving a very impressive SDR (straight delivery rate), vehicles with no defects that go straight to the customer and no delays. TSAM’s Quality assurance network Before condition 100% before QCI 100% 100% Figure 1 This is an example of the QA network for the wire frame wrong or missing part...
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...example, Design for Assembly (DFA) concentrates on the enterprise process of an Assembly that is part of the life cycle production. DFA take into account five to nine key factors associated with the subject product, incorporating part symmetry, weight, fits, size, form features, orientation and so on. It takes into account 5-9 key factors associated with the assembly process such as gripping, special tooling, inserting, equipment, handling and so on (Filippi & Cristofolini, 2009). Careful examination of these issues and their association leads to a better design conclusion with respect of the ease of assembly. Additionally, an atmosphere of teamworking cooperation is formed, thus assembly efficiency is enhanced. The letter X in the DFX is composed of two sections: performance ability and life-cycle processes x. It is a concurrent approach to DFSS, but DFX concentrates on important business elements of concurrent engineering, that is, maximizing the utilization of the scarce resources to the DFSS team. In addition, DFX offers a systematic technique for analyzing design from a spectrum of perspectives. It empowers teamwork within the contemporary DFSS surrounding. The principles of DFX can be discussed through the context of the following DFX tools: * Design for Manufacture and Assembly * Design for Reliability * Design for Maintainability * Design for Serviceability * Design for Life Cycle Cost The Design for Manufacture and Assembly...
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...example, Design for Assembly (DFA) concentrates on the enterprise process of an Assembly that is part of the life cycle production. DFA take into account five to nine key factors associated with the subject product, incorporating part symmetry, weight, fits, size, form features, orientation and so on. It takes into account 5-9 key factors associated with the assembly process such as gripping, special tooling, inserting, equipment, handling and so on (Filippi & Cristofolini, 2009). Careful examination of these issues and their association leads to a better design conclusion with respect of the ease of assembly. Additionally, an atmosphere of teamworking cooperation is formed, thus assembly efficiency is enhanced. The letter X in the DFX is composed of two sections: performance ability and life-cycle processes x. It is a concurrent approach to DFSS, but DFX concentrates on important business elements of concurrent engineering, that is, maximizing the utilization of the scarce resources to the DFSS team. In addition, DFX offers a systematic technique for analyzing design from a spectrum of perspectives. It empowers teamwork within the contemporary DFSS surrounding. The principles of DFX can be discussed through the context of the following DFX tools: * Design for Manufacture and Assembly * Design for Reliability * Design for Maintainability * Design for Serviceability * Design for Life Cycle Cost The Design for Manufacture and Assembly technique offers...
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