7ENT1060 Lean Manufacturing and Services

· Late submission of any item of coursework for each day or part thereof (or for hard copy submission only, working day or part thereof) for up to five days after the published deadline, coursework relating to modules at Levels 0, 4, 5, 6 submitted late (including deferred coursework, but with the exception of referred coursework), will have the numeric grade reduced by 10 grade points until or unless the numeric grade reaches or is 40. Where the numeric grade awarded for the assessment is less than 40, no lateness penalty will be applied

· Late submission of referred coursework will automatically be awarded a grade of zero (0).

· Coursework (including deferred coursework) submitted later than five days (five working days in the case of hard copy submission) after the published deadline will be awarded a grade of zero (0).

· Where genuine serious adverse circumstances apply, you may apply for an extension to the hand-in date, provided the extension is requested a reasonable period in advance of the deadline.

You are to design a continuous assembly process and the supporting part warehouse layout for assembling Skateboards as detailed in the assignment brief which forms part of this document. Submission Requirements:

To be submitted individually, electronically on studynet as PDF documents. This assignment is worth 40 % of the overall in- course assessment for this module. Marks Awarded:

A mark out of 100 which can be broken down as follows:

10 Marks – Calculation for number of operators needed (calculation).

30 Marks - Analysis of assembly time required (as seen in the process charts)

30 Marks – Design of Assembly process and line balancing (as seen in the process charts)

30 Marks – Layout of Assembly Area and Warehouse (Scale Drawing – PDF submission)

A note to the Students:

1. For undergraduate modules, a score above 40% represent a pass performance at honours level.

2. For postgraduate modules, a score of 50% or above represents a pass mark.

3. Modules may have several components of assessment and may require a pass in all elements. For further details, please consult the relevant Module Guide or ask the Module Leader

You are to design a continuous assembly process and layout and the separate supporting part warehouse layout for producing skateboards - to meet the volume requirements of 40 skateboards per hour.

Your assembly process should have the minimum number of operators. You are to design the assembly line layout and separate warehouse layout, as well as each work

station’s work allocation which is to be calculated using the predetermined time allocations provided.

Your submission (a PDF document) should consist of the following:

¨ The Calculation for the number of operators required

¨ Process Charts for each of your operators

¨ A scale drawing of your layout – see below for details

PART A

1. Calculation of Number of Operators (10 Marks)

In this section you are to calculate determine how many assembly stations you will need to meet the volume requirements outlined in the appendices. In order to make this calculation you will need to estimate the time it takes to assemble ONE  skateboard, using the predetermined times supplied in the appendices.

2. Process Charts for each of your operators. (60 Marks)

Using a process chart for each operator, you will need to document every step of the assembly of the skateboards, with the associated time (using the predetermined time allocations provided in the  appendices).

Notes on the process charts:

¨ Each worker is to have a “process chart” (see Chapter 7 of Heizer & Render’s “Operations management”) describing the description, exact time and sequence of each operation.

¨ You should also specify exactly what tools (including Jigs) are needed on each station. Note this in a table for each operator below each process chart.

¨ Include the applicable rest allowance in each process chart. Marks will be awarded for the following:

- Analysis and documentation of assembly time required, using predetermined assembly times provided. (30)

- Design of Assembly process and line balancing (30)

Generate a dimensionally accurate (i.e. scale drawing) of:

A) The layout of the assembly line, showing assembly station locations and material flow. It is not necessary to show the detailed part storage of the actual assembly stations.

B) Provide the layout of the warehouse, assuming:

a. A maximum of one delivery of parts each MONTH – assume 20 working days in a month.

b. ONE shipment of completed skateboards each week. Assume that this could be any day of the week, and that it does not necessarily happen on the same day each week. Assume the line runs for 7 hours per day.

c. All parts received and shipped in boxes (see appendices for each box size).

d. Assume that completed skateboards are put into their own boxes, and boxes are loaded into a pallet which can accommodate 40 completed skateboards.

C) On your drawing, show the precise route of travel of your transporter for each part / assembly being transported. Show each part’s route of travel in a different colour and label the route of travel with the exact total distance that the transporter will need to travel to:

¨ collect the part from the warehouse

¨ deliver to the assembly line

¨ return to starting point.