Manufacturing Strategies and Maintenance Approaches: Widget Ltd Case Study

PLEASE READ ALL INSTRUCTIONS AND INFORMATION CAREFULLY.

This assignment contributes 100% to your final module mark. Please ensure that you retain a duplicate of your assignment. We are required to send samples of student work to the external examiners for moderation purposes. It will also safeguard in the unlikely event of your work going astray.

a) Contrast the similarities and differences between Just in Time (JIT) and Lean manufacturing

b) Critically appraise the various sub-elements of the Just in Time (JIT) manufacturing methodology e.g. reduction of breakdowns (OEE), pull production systems, kanbans (theory and application), machine set-ups and changeovers, inventories etc. highlighting the practical and theoretical implementation of each element

c) Describe a tool or technique which can be used to analyse and improve the performance of manufacturing systems e.g. Rank-order clustering, Ishikawa diagrams, value stream mapping etc. and explain its basic principle, how it would be applied, the potential benefits and inhibitors to implementation.

Equipment Manufacturer) in the Automotive sector. They do this on a Just in time (JIT) / Synchronous basis using a ‘pull’ based manufacturing system. One machine in the process, a 1600 tonne Injection Molding Machine, is causing concern, due to its ‘poor availability’. The company supplies modular subassemblies and this injection machine is crucial to the production operation. By answering the following questions you are to consider the potential strategies that might be deployed and formulate a critical appraisal of the various options that the company has to improve the availability of the Injection Molding machine.

a) Discuss Reliability Centered Maintenance (RCM) and how Widget Ltd. could use it to support improvements to the maintenance approach for their business. (15 Marks)

b) Run to failure is another maintenance strategy that could be adopted by the company. Review and appraise this approach and two other strategies that could be used. You are required to compare and contrast their benefits, disadvantages and considerations required in operation. Also, which would be the most appropriate approach or approaches for the business to improve availability of the injection machine. (15 Marks)

c) Total Productive Maintenance (TPM) is a further methodology / approach that can be used by companies to better manage and maintain their assets. In the context of Widget Ltd, discuss the elements of TPM, and what the requirements are regarding its implementation. You also need to review its components, use, benefits and any assumptions.

Students will need to demonstrate a wide reading around the subject, with good marks being awarded for well-argued, structured answers that are supported by the relevant literature.

• Students may use textbooks or appropriate academic literature (journal articles and conference papers) to support and justify their statements

• References from commercial and other web pages are to be used very sparingly.

• Students can use either Harvard or Vancouver style referencing.

• It is expected that each whole question will have 5 –10 academic references.

• A general reading bibliography is not required

• Students need to demonstrate a clear understanding of the key concepts applicable to the questions and also be able to critically appraise your position/answer, especially when conflicting views have been shown to exist.