Lean Manufacturing APPENDIX A ——— LANCHESTER STAMPING DATA SET Lanchester Company produces several components for vehicle assembly plants. This case concerns one product family, a steel instrument-panel bracket sub-assembly in two types: one each for left hand and right hand drive versions of the same automobile model. These components are sent to the State Street Vehicle Assembly Plant (the customer) PRODUCTION PROCESS Lanchester processes for this product family involve laser cut a metal part followed by welding and subsequent assembly. The components are then staged and shipped to the vehicle assembly plant on a daily basis. = Switching between Type 'LH' (left hand drive) and Type "RH' (right hand drive) brackets requires a 1 hour changeover in laser cut and a 10 minute fixture change in the welding processes. = Steel coils are supplied by Michigan Steel Co in S00f coils. Stee! deliveries to Lanchester arrive on Tuesdays and Thursdays. CUSTOMER REQUIREMENTS * 18,400 pieces per month ~ "12,000 per month of Type ‘LH’ ~ 6,400 per month of Type ‘RH’ * Customer plant operates on two shifts + Palletised retumable tray packaging with 20 brackets in a tray and up to 10 trays on a pallet. The customer orders in multiples of trays. ‘= One daily shipment to the assembly plant by truck. WORK TIME 20 days in a month ‘Two shift operation in all production departments Eight (8) hours every shift, with overtime if necessary Two 10 minute breaks during each shift Manual processes stop during breaks Unpaid lunch Lean Manufacturing VSM page 24Lean Manufacturing LANCHESTER PRODUCTION CONTROL DEPARTMENT + Receives State Street's 90/60/30 day forecasts and ‘enters them to MRP + Issues Lanchester 6 week forecast to Michigan Stee! Co. via MRP * Secures coil steel by weekly faxed order release to Michigan Stee! Co Receives daily firm order from State Street Generates MRP based weekly departmental requirements based upon customer order, WIP inventory levels, F/G inventory levels, and anticipated scrap and downtime ‘+ Issues weekly build schedules to laser cut, welding and assembly processes ‘+ Issues daily shipping schedule to Shipping Department (__ process INFORMATION All processes occur in the following order and each piece goes through all processes. LASER CUT Laser cuts the parts for many Lanchester products ~ Cycle Time: 1 second (60 pieces per minute) = Changeover Time: 1 hour (good piece to good piece) - Machine Reliability: 85% - Observed Inventory: - 5 days of coils before stamping - 4,600 pieces of Type 'LH' finished stampings = 2,400 pieces of Type 'RH' finished stampings ‘SPOT WELD WORKSTATION 1 (dedicated to this product family) Manual process with one operator ~ Cycle Time: 39 second - Changeover Time: 10 minutes (fixture change) - Machine Reliability: 100% - Observed Inventory: ~ 1,100 pieces of Type ‘LH’ - 600 pieces of Type 'RH' ‘Lean Manufacturing VSM page 25Lean Manufacturing ‘SPOT WELD WORKSTATION Il (dedicated to this product family) Manual process with one operator - Cycle Time: 46 second - Changeover Time: 10 minutes (fixture change) - Machine Reliability: 80% - Observed Inventory: ~ 1,600 pieces of Type ‘LH’ - 850 pieces of Type ‘RH’ ASSEMBLY WORKSTATION I (dedicated to this product family) Manual process with one operator ~ Cycle Time: 62 second - Changeover Time: none - Machine Reliability: 100% - Observed Inventory: - 1,200 pieces of Type ‘LH’ - 640 pieces of Type ‘RH’ ASSEMBLY WORKSTATION It (dedicated to this product family) Manual process with one operator - Cycle Time: 40 second - Changeover Time: none - Machine Reliability: 100% - Observed Finished Goods Inventory in Warehouse: ,700 pieces of Type ‘LH - 1,440 pieces of Type 'RH’ SHIPPING DEPARTMENT Remove parts from finished goods warehouse and stages them for truck shipment to customer. Lean Manufacturing VSM poge 26ANOAWT HOOTS ANOLOWS ONIGINWLS NALSSHONVT shou, u spoon pousis = [@] ‘oyeER UI (AIAY SSBB HOM = @ 4d3q ATawassv wo COQ SEB i Fh peal cy Spc, | PR PRPE EY oo coy pone ‘260I015 Sed PepIeNA Coyoedsuy PRPC VTCCS Occece® Cov Cov Cov 0 4d3q ONIGTaM é v v ONIddIHS v v dag 4asv19 Ssaud