Proposed Agenda

• Explination of timestudies.

• Line capacity calculation.

• Manpower planning.

• World class manufacturing cell (Video).

• Line balancing.

Time Study & Line Balancing

1. Conducting a timestudy:

• Identify all the activities of an operation (Welding operation):

• load part in jig, clamp and start cycle (operator).

• robot welding the part (machine auto cycle).

• unload part from welding jig (operator).

• Record the time utilised to perform each activity:

• load the part 10 seconds (operator)

• Welding 40 seconds (robot)

• Unloading 5 seconds (operator)

• Operator allowance 9% of total time: 5 seconds

Total time to produce a part: 60 seconds (60 parts per hour).

• Operations such as leak testing and final checking have no machine time all the time is operator time.

Line Capacity / Hourly Target

Available timeAvailable time per shift:(8hours x 60 minutes) 480Less: Lunch time 30Less: Meeting 10Less: Houskeeping 5

Net available time: 435Less :Planned down time:Robotic Consumable changes: 10%Machine availabilty (100% - 10%) 90%

Total available time:(435 x 90%) 392

Shift Target = (392 minutes / 1minute per part) 392 partsHourly Target = (392 parts / 7.35 hours) 53 parts per hour

Current Layout: Line 1D

Cal.

Cone round weld

FinalRound weld

Tackweld

Cone / inlet pipe tackweld

Cone / inlet pipe tackweld

Leak test

Leak test

Entry

H/shiel clinching

Embos

Spot weld

Heatshield welding

S/ bossrolling

Dr. Wiesner

Final checkExit

Teamleader

Current Layout Line 1D & OutputCurrent Process Flow & Cycle Times

Inlet cone tackweld

Inlet cone tackweld

Calibration 1 1 0.15 Operator dependant 400

Sensor boss rolling 1 1 0.5 120

Cone round weld 1 2 1.35 0.25 89Outlet cone sub assy tack 1 1 0.37 0.1 162Final round weld 2 2 1.34 0.9 90Leak Tester 1 1 0.83 Operator dependant 72Leak Tester 1 1 0.83 Operator dependant 72Heat shield clinching 1 1 0.66 91Heat shield embossingHeat shield spot weldHeat shield weldingHeat shield welding

Dr. Wiesner 1 1 0.69 Operator dependant 87

Final check 1 1 0.8 Operator dependant 75Total Operators: 15

Parts / hourOperation No operators Parts / cycle FTF (min.) Operator Min.

Operator dependant

2 2 0.55 109

1 1 0.52 115

1 0.57Included in first tackweld cycle

1052

Revised Cycle Times & OutputRevised Process Flow: 6-Jun-07

Assumptions:1. Line availability = 80%2. Current bottleneck = 72 / hour at 100%. At 80% availability the revised hourly target = 58 parts / hour.3. Based on current demand the tact time = 51 parts / hour (demand can be achieved in 2 shifts, any increase will require a 3rd shift)

1. Remove one water leak tester from the line.2. Relocate calibrator to sensor boss rolling.3. Swing outlet cone tack station 180 degrees.4. Re-position spot weld closer to clinching.

Inlet cone tackweldInlet cone tackweldCalibration 1 Operator dependantSensor boss rolling 1Cone round weld 2 1.35 0.25 89Outlet cone sub assy tack 1 0.37 0.1 162Final round weld 1 2 1.34 0.9 90Leak Tester 1 1 0.83 Operator dependant 72Heat shield clinching 1 1 0.66 91Heat shield spot weld 1Heat shield embossing 1 Operator dependantHeat shield weldingHeat shield welding

Dr. Wiesner 1 1 0.69 Operator dependant 87

Final check 1 1 0.82 Operator dependant 73Total Operators: 10

1 2 0.55 109

1 0.52 115

105

1 0.65 92

1

1 2 0.57Included in first tackweld cycle

Operation No operators Parts / cycle FTF (min.) Operator Min. Parts / hour

Revised Layout: Line 1D

Cal.

Cone round weld

FinalRound weld

Tackweld

Cone / inlet pipe tackweld

Cone / inlet pipe tackweld

Leak test

Entry

H/shiel clinching

Embos

Spot weld

Heatshield welding

S/ bossrolling

Dr. Wiesner

Final checkExit

Teamleader