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Sonic Speakers Facility Design. Chris Chesla Dan Hovde Tony Niemczyk Mike Rosenthal. Outline. Introduction Approach and Methodology Results Recommendations Conclusion. Introduction. Sonic Speakers purchased new Facility Engineering team New layout New design of production
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Sonic Speakers Facility Design Chris Chesla Dan Hovde Tony Niemczyk Mike Rosenthal
Outline • Introduction • Approach and Methodology • Results • Recommendations • Conclusion
Introduction • Sonic Speakers purchased new Facility • Engineering team • New layout • New design of production • Plan growth for next five years
Approach and Methodology • Current Situation • Lean Manufacturing • Line Balancing • Inventory Control • Layout • Truck Routing
Current Situation • 120,000 square feet • 16 docks • Work 10 hr days 5 days a week
Lean Manufacturing • Used in plant layout • Minimize distances traveled • Balance lines • Assembly lines • Based on pull system • Cross-trained workers • Inventory • Reduce 20%
Line Balancing • Cellular Design • Cross-trained teams • In charge of Quality • Lines • Based on speaker size • Designed to peak demands • Run north to south • Puts finished products close to dock
Inventory Control • ABC inventory Control • Most often used • Easiest to access • Least used • Hardest to access • Rank • A ~ Highest Volume Flow • B ~ Medium Volume Flow • C ~ Lowest Volume Flow
Plant Layout • Warehouse • 27,500 square feet including aisle • 12 foot aisles • Stack three pallets high • Wood and Carpet stored separate • Located near production • Assembly located in center • Easy access to all areas
Truck Routing • 15 routes • 6 to 7 orders per truck • Shipped 3 times a week • Filled in reverse order
Results • Tact times • Yellow ~ 24 min • Blue ~ 28.09 min • Green ~ 28.09 min • Red ~ 73.34 min • Line efficiencies
Results Cont. • Reduction of Inventory
Recommendations • Short-term • Purchase necessary items • Classify inventory • Arrange inventory • Develop truck routes • Manage Flow • Long term • Diminish Inventory • Improve line efficiency • Multifunctional work staff
Conclusion • Cellular manufacturing • Engineered plant layout • Lean Manufacturing • Decline inventory • Reduce travel • Inside the plant • Outside the plant