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IE 376 – Project Assignment

IE 376 – Project Assignment. Ford Motor Company Plastics Division JIT implementation. The Sandusky, Ohio, plastics plant. Produces head, side and tail lamps, temperature switches and door latches for air cleaners Tail lamps Lens, clips, studs, butyl, gaskets (purchased) Body (produced).

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IE 376 – Project Assignment

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  1. IE 376 – Project Assignment Ford Motor Company Plastics Division JIT implementation

  2. The Sandusky, Ohio, plastics plant • Produces head, side and tail lamps, temperature switches and door latches for air cleaners • Tail lamps • Lens, clips, studs, butyl, gaskets (purchased) • Body (produced)

  3. Tail lamp production Molding Painting Assembly Packing Shipment

  4. Molding department • 19  700 ton machines ($900000) • 2  1000 ton machines • 8 different types of molds ($100000) • The types of molds required for each model, the types of the cavities and the cycle time in seconds are provided. • Exhibit 4: Escort 540 (2 available) 2 54 Thunderbird 642 (left side only) 1 69

  5. Molding department (cont’d) • The press assignment for each mold type is provided. (for a day) • Exhibit 5: m/c no.m/c typemolds assigned 30 700 569 479 639 • The setup times: • 45 min, 1 hour 45 min, 4 hours • Tail lamp production is 10% of the total workload of 21 machines (page 7)

  6. Molding department (cont’d) • The production plan for each mold type is provided. (for a week) • Exhibit 6: moldweekly schedule (units) 539 2874 • Mold cycle time for mold type 539 is 54/2=27 seconds/unit

  7. Painting • Two lines • 700-900 units per hour per line can be produced • The setup time is 3-5 minutes • Only one shift • 8 workers

  8. Assembly • Two flexible assembly systems • Two shifts • Setup time 20-30 minutes • Standard production rates for each model are provided. • Exhibit 8: Part namenet 8 hr standardcycles/hr Escort Rear (R&L) 2780 450

  9. Shipping • Rails and trucks are used for shipments. • One week’s daily shipping schedule for each model is provided in exhibit 9. • The assembly plant locations are provided in exhibit 3. ModelMon.Tues.Wed.Thurs.Fri. Lynx 241 90 411 90 411 Lynx is produced in Canada and New Jersey

  10. Planning • 4-week plans (20 production days) • Weekly tail lamp production requirement schedule by month for each model is provided in exhibit 2. AIM: • To operate under just-in-time philosophy.

  11. What do we want from you? • Evaluate the performance of the existing system under JIT philosophy. • What are the problems at each stage (from purchasing to shipping)? • How can you solve the problems mentioned above?

  12. What do we want from you? (cont’d) • We provide some questions, which will help you to analyze the system. • Find some other key questions • Answer the questions • Support your ideas by using the information provided in the text. • Show calculations when necessary • You can make assumptions, but state them in your report • Write an engineering report.

  13. Example • The problem: The capacity is not enough to satisfy the demand in department X. • Show that demand > capacity • How did you calculate the capacity? • Solution method: Buy a new machine • Is the investment cost justified?

  14. Office Hours • Esra Koca • Office: EA330 • Office Hours: April 15, 12:30 - 14:30April 29, 12:30 - 14:30 • Özge Şafak • Office: EA327 • Office Hours : April 17, 13:00 - 15:00 April 24, 13:00 - 15:00

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