Skateboard Assembly Process and Warehouse Layout Design

Penalties for Late Submissions

· 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.

This Assignment assesses the following module Learning Outcomes:

 * examine the role of Operations Management, the operational processes, planning and control systems employed within a business environment; of organisations;

* assess the relationships between operations management and other functions in the context of constraints;

* illustrate the results of analysis and synthesis in an appropriate business format individually and as a group

Assignment Brief:

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.

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.

General Notes and Requirements:

1. Assume there are no lunch / tea breaks – assume a uniform production rate with no stoppages, (Monday - Friday)

2. In the warehouse, show the location for skateboards as an appropriately sized and dimensioned area.

3. Aisles should be a minimum of 2m wide to allow for access. Assumed that boxes of parts are delivered by a person pushing a trolley size 500x700mm

4. Assume the warehouse area is separate but adjoining to assembly area with a 3m wide doorway in the wall that separates them. The position of the doorway can be anywhere along this wall.

5. Assume that all storage is not stackable (i.e. no shelves) – assume that the boxes are simply placed on the floor in the appropriate place.

6. Assume that boxes cannot be stacked.

7. Assume that empty boxes are automatically returned to a separate warehouse – there is no need to account for their handling, storage or disposal.

8. Fasteners must be “hand threaded” before being fastened with a power tool.

9. Assume that suitable jigs are available in which to place the skateboard on each station, and therefore the operator does not need to hold the assembly while fitting parts once the assembly has been placed in the jig.

10. Assume that each skateboard is put into its own cardboard box. Assume that the carboard boxes are supplied flattened and are unfolded at the workstation by the operator. The operator then inserts the board in to the carboard box and seals the package with tape.