Copy of group 8 plug report

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  • 1. http://www.gameswala.com/PRODUCTION MANAGEMENT Lucky Seven Process Flow Design For Assembling of Electric Plug http://www.gameswala.com/
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  • 3. 1. PROCESS FLOW DIAGRAM: P I 3 Pins W 1 Plastic Base 3 Dual Screws Fix the Dual Screws to Plastic Base Attach the Pins to Dual screws with Automated Screw Driver P 2 Small Screws WI 1 Strip Attach the strip using screws to the base with Automated Screw Driver P 2 Big Screws I W 1 Small Screw Fix the screws in the Dual Pins from inside 2 Big Screws P I Wire Holder W Plastic Cover Packaging Material Place the wire Holder & fix the Cover to Base with screws Making Boxes P I W 3
  • 4. Polythene Bag Packaging BoxThis design has been made keeping in mind that the following raw materials are being procuredfrom outside. Lucky Seven Inventory for One Plug: G F Packaging  1 Plastic Base  1 Plastic Cover  1 Big Pin  2 Small Pins  3 Dual Screws  4 Big screws  3 Small Screws  Wire Holder  Strip  Packaging Box  Polythene bag2. CRITICAL DESIGN CONSIDERATIONSIn our design for the Lucky Seven Plug Production Line, we are starting the production using twoparallel lines, each having the maximum capacity of over 15000 plugs per day. The whole process is amanual process, with only the screw-drivers being the automatic ones.The design considerations for keeping two parallel lines of production having capacity more than therequired output, is to keep the margin for the growth in the variety and volumes of the plugs.Currently, each line will be used to produce 10000 plugs per day; and the whole process is designedto run in 2 shifts of 8 hours each. Initially when the production required is lesser than the designcapacity, the number of workers can be reduced so as to increase the cycle time and therebyreducing the capacity.Keeping the future expansions in view, a factor of safety in calculating the capacity is taken to bearound 1.5 i.e. to say an allowance of 50% expansion in future is provided.3. RATIONALE FOR THE DESIGNGiven : Capacity required = 18000 – 20000 units per day Variety = Presently only one type (Will increase in future)Assumptions: • Assumed Factor of Safety = 1.5 (to take care of the future expansions)  Total capacity required = 20000 x 1.5 = 30000 approx. 4
  • 5. • Number of Shifts = 2 • Hours in a Shift = 8 • Number of Production Lines = 2 (to take care of the variety in future)Times for Various Processes: Time Time taken per worker S. No. Process Taken Number of Workers (sec) (sec) 1 Fixing 18 5 3.6 2 Screwing 2 1 2 3 Screwing 12 4 3 4 Fixing from inside 10 3 3.3 5 Placing the top 8 3 2.7 6 Packaging 6 2 3 • Bottleneck Process = Fixing (18 secs) • Cycle Time = 18 / 5 = 3.6 secs • 1 Shift = 8 hrs = 8 x 60 mins = 480 x 60 secs = 28800 secs  Production capacity = 28800 / 3.6 = 8000 units per shift per line  Total Production Capacity = 8000 x 2 x 2 = 32000 units per day4. COMPARISON OF DESIGNWe have employed Assembly line manufacturing process. It is a production arrangement of workersand equipment in which the product that is being assembled passes consecutively from operation tooperation, with each station adding to the work of previous stations, until the product is completed.We have used the concept of "concurrent processes"—multiple parallel activities that feed into afinal assembly stage. Here the packing box is derived from another process that makes the box andpacking material.We have also used the concept of Just-in-time (JIT) manufacturing methods. Here our plant wouldcarry only one or a few days worth of inventory, relying on suppliers to provide parts and materialson an "as needed" basis.We have assigned the screwing processes to different individuals instead of a single individual whichcould have been possible had we used a U-Shaped assembly line, due to the fact that if some delaycrops into the second screwing process, it might lead to mismanagement of the first screwingprocess as well. To combat this menace, it is useful to use the proposed design. It should be notedthat assembly lines dont increase the speed of producing a single unit, but only increases rate whenthere are a stream of units to be produced.Modular Assembly is an advanced assembly line method that is designed to improve throughput byincreasing the efficiency of parallel subassembly lines feeding into the final assembly line. This hasbeen used in the packing process as explained above. This saves the time required to assemble thepackaging box. 5
  • 6. We have done a comparison with some other designs:Cell Manufacturing: This production methodology has evolved out of increased ability of machines to perform multiple tasks. Cell operators can handle three or four tasks, and robots are used for such operations as materials handling and welding. We have not used it as robots and other advanced machines are not a necessary requirement for our process. Moreover a worker is not given more than one job due to the reasons explained above.Team Production: Team-oriented production is another development in assembly line methods. Where workers used to work at one or two-person per work stations and perform repetitive tasks, now teams of workers can follow a job down the assembly line through its final quality checks. This has been eliminated to keep the production time short.Disadvantages of our design:• Workers might feel alienated and bored because of the repetition of the same specialized task all day long.• Because workers have to stand in the same place for hours and repeat the same motion hundreds of times per day, repetitive stress injuries might occur.• Another issue is that if there is a snarl in production at one work station, it will have an impact on the entire assembly line, potentially bringing it to a halt until the situation can be fixed.We intend to overcome these difficulties by means of regular inspection and welcoming workerinput and thoughts on ways to make the assembly line and the product better. If a worker isunavailable to work due to any reason there is always “bench strength” to backup.5. WORK METHODS ENSURING QUALITY PRODUCTOur choice of suppliers who all comply with quality standards like IS 1293 (for plugs parts, cable reelsetc.) is our prime work method which ensures quality final product. • Our choice of working tools like certified automated screwdrivers etc. ensure proper operations with uniform results through out. • Our uniform skilled labor ensures minimal faults and quality products. Everyone knows exactly what his or her own responsibilities are. • Our uniform supplier chain understands our expectations with respect to quality and hence delivers raw materials likewise. • Our dedication towards 5S methodology helps us keep our workplace organized and hence keeps our efficiency high towards quality products. • Our general standardized and consistent working method and approaches ensure consistently high quality products. • Our regular feedback system both from the retailers and direct customers ensure high quality. 6
  • 7. • Our implementation of kaizen philosophy helps us improve throughout the process. 7
  • 8. 6. WORK METHOD ANALYSISThe process in consideration for the work method analysis is the first Screwing Process.RIGHT HAND LEFT HANDSTEP OTIDS DESCRIPTION STEP OTIDS DESCRIPTION1 Hold screw driver 1 Move Hand2 Hold screw driver 2 Grab the piece Raise to a comfortable3 Hold screw driver 3 height Move screw driver to 1st4 4 screw Hold the piece Fit screw driver on the5 5 screw Hold the piece6 Press the button 6 Hold the piece7 Release the button 7 Hold the piece nd Move screw driver to 28 8 screw Hold the piece Fit screw driver on the9 9 screw Hold the piece10 Press the button 10 Hold the piece Hold the piece11 Release the button 11 Move screw driver to12 12 3rd screw Hold the piece Fit screw driver on the13 13 screw Hold the piece14 Press the button 14 Hold the piece15 Release the button 15 Hold the piece16 Move the hand away 16 Hold the piece Move the piece to next17 17 Hold the screw driver in line Keep the piece in the18 18 pile of semi assembled Hold the screw driver plugsRelaxation Allowance: 8
  • 9. A. Physical Strains A.1 Average force exerted : 0 A.2 Posture :4 A.3 Vibration :4 A.4 Short Cycle : 10 A.5 Restrictive Clothing :0 B. Mental Strains B.1 Concentration/Anxiety : 4 B.2 Monotony : 11 B.3 Eyes Strain :2 B.4 Noise :0 C. Physical or mental strains resulting from the nature of the working conditions. C.1 Temp & Humidity :8 C.2 Ventilation :0 C.3 Fumes :0 C.4 Dust :0 C.5 Dirt :0 C.6 Wet :0 Total : 43 As per the points conversion table: 20% Hence our relaxation allowance is 20%7. MEASURES TO MONITOR AND MANAGE THE PRODUCTION LINEVarious measures can be there to monitor and manage the production line.Our process is designed to be highly efficient, and very cost effective. The workers focus on a smallpart of the overall whole. Since there is very little machinery involved, the downtime losses are veryless. Also since it is only an assembling process and not a manufacturing one, the quality losses willbe very less. So an overall efficiency of about 94% can be taken.32000 x .94 = 30080 (which is approximately what is required)Apart from this the Process Capability of about 1.5 will be tried to achieve and maintain.The process is also expected to be somewhere between 4 sigma and 5 sigma. 9