Assignment 2b (Individual Assignment) · Web viewIn 2009 as the world's economy was in the midst of...

Assignment 2b (Individual Assignment)

ContentsAssignment 2b (Individual Assignment)...................................................................................1

Scenario..................................................................................................................................2Context...................................................................................................................................3General Company Background..............................................................................................3The Production Process..........................................................................................................3

Examples of typical products (flanges)..............................................................................4Facility Layout...................................................................................................................5Product route......................................................................................................................6Current Value Stream Map................................................................................................8

Appendix................................................................................................................................9Current Value Stream Map..................................................................................................15Flange Production: Saw Cutting Process Data.....................................................................16Administrative Process.........................................................................................................17

Table of FiguresFigure 1 Aerial photograph of Evenort. (Building with white roof.)........................................2Figure 2 0.75" Diameter Flange.................................................................................................4Figure 3 16" Diameter Flange....................................................................................................4Figure 4 Shop Floor Layout.......................................................................................................5Figure 5 Production Route 1......................................................................................................6Figure 6 Manufacturing Process and Product Route..................................................................7Figure 7 Current Value Stream Map..........................................................................................8Figure 8 Product Route 1.........................................................................................................10Figure 9 Product Route 2.........................................................................................................11Figure 10 Product Route 3.......................................................................................................12Figure 11 Product Route 4.......................................................................................................13Figure 12 Some ideas for improving the site...........................................................................15

1

Scenario

Manufacturing and logistics industries involve the movement of physical items through a series of processes and acted upon by discrete resources. Being aware that industry is under constant pressure to provide high quality, timely products while utilising the minimum of resources you are required to research and apply appropriate Lean Tools and techniques within Evenort, a small manufacturing business situated based in South Yorkshire. Thereby helping the business better identify and remove waste. Below, Figure 1, is an aerial photograph of Evenort's premises. It should be noted from the photograph that there is little room for expansion as there is a train track behind the factory and buildings on either side. It may be possible to extend the building towards the main road if required.

Figure 1 Aerial photograph of Evenort. (Building with white roof.)

2

Context

In 2009 as the world's economy was in the midst of recession Evenort, an SME based in South Yorkshire, was seeking to increase efficiency within the business through implementing a process improvement strategy. In conjunction with Sheffield Hallam University a Knowledge Transfer Partnership was entered into providing the opportunity to change. Lee, the Knowledge Transfer Associate having an awareness of Lean, 6 Sigma, and discrete-event simulation has the opportunity to make significant improvements to the bottom line of the business; but before making any change to the business he must first identify what improvements could be made and devise a strategy for making those improvements. What could, where would you and in what order would you implement changes? Make your recommendations.

The Evenort Case is intended for using on a process improvement course. The normal participant is recent graduate who may be taking this module on a full or part-time basis and has little prior exposure to the practical side of process improvement.

General Company Background

Incorporated in Sheffield in 1982, Evenort is currently situated over two sites. The Head Office and main manufacturing site is at Houghton Road, Dinnington, Sheffield, S25 4JJ, UK. With its plasma cutting workshop based at: Shop 12, Robert Jenkins Works, Wortley Road, Rotherham, S61 1LT, UK.

Evenort's commitment to manufacturing excellence has established the company as a reliable partner in the processing of Stainless Steel. Evenort's business proposition is to supply high value bespoke products, typically flanges, produced within 24hours of order, to the highest quality standards and manufactured from alloys appropriate to the environment, be it sour or acidic. As such their products are often used in the oil and gas industries.

The Production Process

Evernort offers a range of products and services which includes: Steel & Alloy Flanges Bar Processing Advanced Manufacturing Deep Water Shipments Plasma Cutting

However, the focus of this case study is Evenort's Head Office where flanges are machined, either from cut bar or semi finished castings.

3

Semi finished forgings are usually purchased from Hilton Metal Forging Ltd. based in India of whom Evenort owns a substantial share of and is the official UK agent.

Examples of typical products (flanges).

The flanges come in a variety of sizes but typically range in size from 98mm Dia to 597mm Dia and are manufactured from stainless steel. Figure 2 and Figure 3 illustrate and provide schematics of the products.

0.75" ASA 150LB RFSO 316/L

Dimensions in mm

D K L C N H B R O F No.Holes98 69.8 15.9 12.7 38 15.9 27.7 3 42.9 1.6 4

Figure 2 0.75" Diameter Flange

16.00" ASA 150LB RFSO 316/L

Dimensions in mm

D K L C N H B R O F No.Holes597 539.8 28.6 36.5 457 63.5 410.5 9.5 469.9 1.6 16Figure 3 16" Diameter Flange

4

Facility Layout

The manufacturing facility has grown and expanded as demand for specific products has increased. This led to equipment being purchased and located where there was space, which Lee thinks may or may not be in the best location from a process efficiency point of view. The current layout can be seen in Figure 4.

Figure 4 Shop Floor Layout.

5

[Machine] Saw:HA500, HA700, HA400 (6 machines), HA250 (6 machines) Turning Machine:CNC Turning: CNC-T1, CNC-T2, CNC-T3, CNC-T4, CNC-T&D5 Manual Lathe: M-L1, M-L2, M-C-L3, M-L4, M-L5Adv CNC Turning&Drilling: INT200, INT300Drilling Machine:CNC-D1, CNC-D2, CNC-D3, CNC-D4, CNC-D5VAX500 (mill and drill)Mark:Mark 1, Mark 2, Mark 3, Mark 4Crane:Crane 1, Crane 2, Crane 3[OP]DayShift 12 operatorsNightShift 5 operators+1 laybour[Delivery]

VAX500

INT200

INT300Bar Stock

Area

Bar Stock Shelf

Saw HA250 (6) Saw HA400

(6)

Saw HA700

Saw HA500

ScrapCoolant &

Oil Scrap

CNC-D5

CNC-T&D5

Crane 3

Crane 2

Crane 1

Office

Forged flanges container

Inspect

Mark

Packing

OfficeForge Stock Shelf ML2

ML4

CNC-T4

CNC-T3CNC-T1 CNC-D3

CNC-D1

CNC-D4

CNC-D2CNC-T2

ML5

ML1

MCL3

Product route

Lee has spent several weeks collecting data and has been able to identify four different routes through the factory. The first of which is shown in Figure 5 with the remainder given in the appendix.The generic process route consists of Sawing the bar to length (if manufactured form bar and not from a semi finished forging), turning, drilling, inspecting, marking and packing.

PRODUCT ROUTE 1 (Ø75-Ø340mm, Stainless Steel 304, 316)

Bar

Saw Cutting OperationOP M/C Job Size Cycle Time Changeover Conditions for changeover Blade Band change Conditions for change

Day Night

1 1

HA250 Ø75-Ø200mm 10mins ± 2

15mins±5 Assume after 500 cuts

HA400 Ø152-Ø355mm 10mins ± 2

1 person in charge all the saws

Turning OperationOP M/C Job Size Cycle Time Changeover Conditions for changeover Tool/Tip change Conditions for change

Day Night

1 0.5CNC-T1 Ø75-Ø150mm 5mins ± 3 5mins ± 2

Your assumption for batch size 1 minCNC-T3 Ø125-Ø254mm 5mins ± 3 5mins ± 2CNC-T4 Ø125-Ø254mm 5mins ± 3 5mins ± 2

1 1 ML-1 Ø75-Ø340mm 15mins ± 5 5mins ± 21 0 ML-2 Ø75-Ø340mm 15mins ± 5 5mins ± 2

Note: means at night shift 1 person on both turning and drilling machine

Drilling OperationOP M/C Job Size Cycle Time Changeover Conditions for changeover Tool/Tip change Conditions for change

Day Night

1 0.5CNC-D2 Ø75-Ø400mm 3mins ± 1 5mins ± 2 Your assumption for batch size

1 minCNC-D3 Ø75-Ø400mm 3mins ± 1 5mins ± 2CNC-D4 Ø75-Ø400mm 3mins ± 1 5mins ± 2

Inspection, Mark & PackOP M/C Job Size Cycle Time Changeover Conditions for changeover

Day Night

2 operators0.5 0 Inspect Station All jobs 30secs±5

Assume no changeover1.5 0 Mark 1 Ø75-Ø380mm 20secs±5Mark 2

see cutting process data

Normally change per batch. Batch size varies very much depending on customer order quantity (could be from 1 to 200), make your own assumption.

Forged Flange

Make your own assumption. E.g. change tip when finish 50 items.

Make your own assumption.

Figure 5 Production Route 1

6

An alternative representation of the process route can be seen in Figure 6.

Parker Job

Big Job

Note:

EVENORT MANUFACTURING PROCESS & PRODUCT ROUTE

Main Process

Machine and Product Route

Main process

Product route

Second route

1. Jobs are scheduled daily when customer orders are received. 2. Generally, product route is determined by the size instead of type, but product with complicated shape only goes to advanced CNC machine. 3. and, duplex steel and nickel alloy product only goes to advanced CNC machine.

CNC-Turing

Adv. CNC–T&D

Manual Lathe-T

SawBar

CNC-T1 (Ø75-Ø150mm)



M-L1 (Ø75-Ø340mm)


M-L2 (Ø75-Ø340mm)

M-C-L3 (Ø75-Ø340mm)

M-L4 (Ø300-Ø520mm)

M-L5 (Ø500-Ø700mm)

INT200 (Ø75-Ø200mm)

INT300 (Ø175-Ø380mm)

Turning (Boring, Facing, Taping, etc.) Drilling (Bolt Hole)

CNC-T&D5 (Ø340-Ø1200mm)

CNC-D1 (Ø300-Ø640mm)





Inspection Marking Packing

VAX-500(Ø75-Ø380mm)

HA500

Forges

HA700

HA400 (5 M/C)

HA250 (5 M/C)

Mark 1

Mark 2

Mark 3

Mark 4

Figure 6 Manufacturing Process and Product Route.

7

Evenort Current Value Stream Map

BARSAW

112 M/C

C/T

C/O

Uptime

Shifts=2

Avail.=25920 secs

CNC TURNINGT1, T3, T4

Day 1, Nigt 0.5M/C Day 3, Nigt 1

MANUAL LATHEML1, 2 ML3 (center)

Day 2 Nigt 1M/C Day 2, Nigt 1

ADV.CNC TURNING & DRILLING INT200

Day 1, Nigt 0.41 M/C

DRILLING D2, 3, 4


INSPECTION

0.5

C/T

C/O

Uptime

Shifts=1

Avail.=25920 secs

MARK

1.5 4 M/C

C/T

C/O

Uptime

Shifts=1

Avail.=25920 secs

PACKAGE

0.5 0.5 for dispatch

C/T

C/O

Uptime

Shifts=1

Avail.=25920 secs

EVE. (10%) Weekly

TNT (90%) Daily

Customers

Pieces/wk= 1134

Pieces/Day =225

Takt= 231 secs

PRODUCTIONCONTROL

Daily ScheduleBars

Sandvik and etc.

Weekly

4mths

0.3 days

Orders

1 month Schedule

Order as Reuqired

1.5 days 0.4 days 0.2 days

Forge FlangesHMFL(India) andSL, DSF (China)

2 wks

6Weeks

Ship

Staging

0.5days

DailyWork Routine / Inspection

ADV.CNC Milling& DRILLING


C/T

C/O

Uptime

Shifts=2

Avail.=25920 secs

Ø75-Ø250 3M/C

CNC TURNING & DRILLING

0.51 M/C

C/T

C/O

Uptime

Shifts=2

Avail.=25920 secs

Ø75-Ø340 3M/C

Ø75-Ø200 1M/C

Ø300-Ø640 2M/C

Ø220-Ø457 1M/C

Ø175-Ø380 1M/C

Ø340-Ø1200 1M/C

CNC TURNING T2

0.2 only day shift1 M/C

MANUAL LATHE ML4, 5

1 only day shift 2 M/C



DRILLING D5

0.3 day shift1 M/C

Bar FlangesForge Flanges

Current Value Stream Map

From compiling the above data and direct observation Lee has created the following Value Stream Map, Figure 7.

8Figure 7 Current Value Stream Map

Appendix

9

PRODUCT ROUTE 1 (Ø75-Ø340mm, Stainless Steel 304, 316)

Bar


Day Night

1 1

HA250 Ø75-Ø200mm 10mins ± 2


HA400 Ø152-Ø355mm 10mins ± 2


Turning OperationOP M/C Job Size Cycle Time Changeover Conditions for changeover Tool/Tip change Conditions for change

Day Night

1 0.5CNC-T1 Ø75-Ø150mm 5mins ± 3 5mins ± 2

Your assumption for batch size 1 minCNC-T3 Ø125-Ø254mm 5mins ± 3 5mins ± 2CNC-T4 Ø125-Ø254mm 5mins ± 3 5mins ± 2

1 1 ML-1 Ø75-Ø340mm 15mins ± 5 5mins ± 21 0 ML-2 Ø75-Ø340mm 15mins ± 5 5mins ± 2

Note: means at night shift 1 person on both turning and drilling machine

Drilling OperationOP M/C Job Size Cycle Time Changeover Conditions for changeover Tool/Tip change Conditions for change

Day Night

1 0.5CNC-D2 Ø75-Ø400mm 3mins ± 1 5mins ± 2 Your assumption for batch size

1 minCNC-D3 Ø75-Ø400mm 3mins ± 1 5mins ± 2CNC-D4 Ø75-Ø400mm 3mins ± 1 5mins ± 2


Day Night

2 operators0.5 0 Inspect Station All jobs 30secs±5

Assume no changeover1.5 0 Mark 1 Ø75-Ø380mm 20secs±5Mark 2


Normally change per batch. Batch size varies very much depending on customer order quantity (could be from 1 to 200), make your own assumption.

Forged Flange


Make your own assumption.

Figure 8 Product Route 1

10

Day NightHA250 Ø75-Ø200mm 10mins ± 2HA400 Ø152-Ø355mm 10mins ± 2


Day Night

1 0.4 Mazak INT 200 Ø75-Ø200mm 10mins ± 5 15mins ± 5

1 0.3 Mazak INT 300 Ø175-Ø380mm 20mins ± 10 15mins ± 5

Day Night

1 0.3 Mazak VAX 500 Ø75-Ø380mm 45mins ± 15 20mins ± 5 Your assumption for batch size 1 minMake your own assumption.

Day NightInspect Station All jobs 30secs±5Mark 1Mark 2

Mark 3For top face marking, make assumption

Pack Station All jobs 25secs±5

Assume no changeover


Tool/Tip change Conditions for changeOP M/C Job Size Cycle Time Changeover Conditions for changeover

Forged Flange

OP M/C Job Size Cycle Time


Depends on order quantity (1 to 200), make assumption


Milling Operation (Optional depends on custmer requirment, assume 50% of parts needs milling opteration)

Turning & Drilling Operation

Changeover Conditions for changeover Tool/Tip change Conditions for change

Note: 1 OP on 3 machine at night, the figures are assumption work loading distribution.

Your assumption for batch size 1 min


Ø75-Ø380mmSampe operators with Route 1

20secs±5

PRODUCT ROUTE 2 (Adv. CNC Ø75-Ø380mm, assume 40% Duplex and Nickel Alloy, 60% stainless steel)

Bar


1 1


11

13

Day NightHA500 Ø304-Ø457mm 10mins ± 2HA700 Ø406-Ø640mm 10mins ± 2


Day Night

CNC-T2 Ø220-Ø457mm 15mins ± 5 5mins ± 2

ML-4 Ø300-Ø640mm 25mins ± 5 10mins ± 5ML-5 Ø300-Ø640mm 25mins ± 5 10mins ± 5

Day Night

CNC-D5 Ø75-Ø580mm 7mins ± 2 5mins ± 2 Your assumption for batch size. 1 minMake your own assumption.

Day NightInspect Station All jobs 60secs±5

Mark 4 Ø400-Ø1200mm30secs±5


Tool/Tip change Conditions for changeOP M/C Job Size Cycle Time Changeover Conditions for changeover

Assume after 200 cuts

Drilling Operation

Turning OperationForged Flange

OP M/C Job Size Cycle Time Changeover Conditions for changeover Tool/Tip change Conditions for change

Your assumption for batch size 1 min


1 1 see cutting process data

Depends on order quantity (1 to 50), make assumption

20mins±5

PRODUCT ROUTE 3 (Ø380-Ø640mm stainless steel 304, 316)

Bar


Sampe operators with Route 1

1 0

same OP on CNC-T1, T3, T4

Same OP on CNC T&D5




Day Night

1 1 HA700 Ø400-Ø640mmsee cutting process data

10mins ± 2Depends on order quantity (1 to 20), make assumption



Day Night

1 1 CNC T&D5 Ø400-Ø1200mm180 mins ± 60 10mins ± 3Depends on order quantity,

make assumption1 min

Make assumption. E.g. after 20 items

(Ø400-Ø1200mm)

Day Night

Inspect Station All jobs 60secs±5

Mark 4 Ø400-Ø1200mm30secs±5


Forged Flange



Sampe operators with Route 1

Turning & Drilling OperationOP M/C Job Size Cycle Time Changeover Conditions for changeover Tool/Tip change Conditions for change

Conditions for change

PRODUCT ROUTE 4 (Ø400-Ø1200mm, majority stainless steel 304, 316)

Bar (Ø400-Ø640mm)

Saw Cutting OperationOP M/C Job Size Cycle Time Changeover Conditions for changeover Blade Band change


14

Current Raw Material Inventory and WIP for Reference to Make Batch Size Assumptions

Bar

Route 1

For CNC-T1,T3,T4 For CNC-D2, D3, D4 For Inspect For Mark For Pack

2 weeks stock 137 parts, 1 to 10 types of parts79 parts, 1 to 7 types of parts 20 0 45

Forge For M-L1, L24 months stock 64 parts, 1 to 10 types of parts

Route 2

For Mazak INT 200 For Mazak VAX 500 5 10 10

40 parts, 1 to 5 types of parts77 parts, 1 to 5 types of parts

For Mazak INT 30017 parts, 1 to 3 types of parts

Route 3For CNC-T2, M-L3, L4 For CNC-D5 4 0 4

16 parts, 1 to 5 types of parts6 parts, 1 to 2 types of parts

Route 4For CNC-T&D5 6 0 06 parts, 1 to 4 types of parts

Note: This inventory and WIP is just for reference so that you have an rough idea when you make assumption on batch size.

The WIP of parts number for different operation and types number varies day by day. They are average figures based on my one week statistics.

15

Evenort Current Value Stream Map

BARSAW

112 M/C

C/T

C/O

Uptime

Shifts=2

Avail.=25920 secs

CNC TURNINGT1, T3, T4


MANUAL LATHEML1, 2 ML3 (center)

Day 2 Nigt 1M/C Day 2, Nigt 1



DRILLING D2, 3, 4


INSPECTION

0.5

C/T

C/O

Uptime

Shifts=1

Avail.=25920 secs

MARK

1.5 4 M/C

C/T

C/O

Uptime

Shifts=1

Avail.=25920 secs

PACKAGE

0.5 0.5 for dispatch

C/T

C/O

Uptime

Shifts=1

Avail.=25920 secs

EVE. (10%) Weekly

TNT (90%) Daily

Customers

Pieces/wk= 1134

Pieces/Day =225

Takt= 231 secs

PRODUCTIONCONTROL

Daily ScheduleBars

Sandvik and etc.

Weekly

4mths

0.3 days

Orders

1 month Schedule

Order as Reuqired

1.5 days 0.4 days 0.2 days

Forge FlangesHMFL(India) andSL, DSF (China)

2 wks

6Weeks

Ship

Staging

0.5days

DailyWork Routine / Inspection

ADV.CNC Milling& DRILLING


C/T

C/O

Uptime

Shifts=2

Avail.=25920 secs

Ø75-Ø250 3M/C

CNC TURNING & DRILLING

0.51 M/C

C/T

C/O

Uptime

Shifts=2

Avail.=25920 secs

Ø75-Ø340 3M/C

Ø75-Ø200 1M/C

Ø300-Ø640 2M/C

Ø220-Ø457 1M/C

Ø175-Ø380 1M/C

Ø340-Ø1200 1M/C

CNC TURNING T2

0.2 only day shift1 M/C

MANUAL LATHE ML4, 5

1 only day shift 2 M/C



DRILLING D5

0.3 day shift1 M/C

Bar FlangesForge Flanges

Current Value Stream Map

Figure 12 Some ideas for improving the site

16

Flange Production: Saw Cutting Process Data304, 316 Material Bar Saw Cutting Data

Bar Size (Ømm) Saw Type Used for Cutting Cutting Time (mins) Varation76 3 ±1828895

101 5 ±1107114120 HA250127133139152 10 ±2165177185190200 17 ±3203215220228 HA400241254 25 ±4279285304 38 ±4340355 59 ±5381 HA500406 75 ±6431457 100 ±7520 HA700 150 ±8580640 220 ±10

Duplex Steel e.g. F44 and Nickel Alloy e.g. 625 Material Bar Saw Cutting Data76 4 ±1828895

101 10 ±2107114120 HA250127133139

17

152 22 ±3165177185190200 37 ±4

Administrative Process

Physical equipment in process

4 x PC for orders (4 staff)1 printer - job sheets (carbon paper)1 printer - WRI cards, drawings, test certificates (normal)1 PC - Diana/Peter -digital filing, printing(Peter also has PC but not necessarily required for this particular process)

18

Start

Order received

PO required?

Inputdetails into unityRaisePO

Jobsheet printedWRI card & drawing

printed

Drawingadequate?

Jobwritten in job sheet log book

Reprint or print drawing

Jobsheet placed in blue tray

Jobsheets sorted into days

Job complete?

Marksheet to indicate job complete

Locaterequired material

Document pack out together

Test certificate printed

Inspection note & test certificate filed

digitally

Jobsheettop copy to dispatch / invoicing

Document pack matched with

completed part

Allcorrect documents with finished part?

Partdispatched with documentation

Printmissing documents

Locatepart

Process customer payments

White top sheet filed

End

NoYes

Yes

No

Yes

No

Yes

No

Assignment 2b (Individual Assignment) · Web viewIn 2009 as the world's economy was in the midst of...

Documents

Transcript of Assignment 2b (Individual Assignment) · Web viewIn 2009 as the world's economy was in the midst of...