Lean Manufacturing Implementation and Analysis for Acme Machining

This project presents a comprehensive analysis of Acme Machining Company's manufacturing processes, focusing on the application of lean manufacturing principles. It begins with an introduction to the company and its operational context, including a case study of a disc brake product family. The core of the project involves the creation and analysis of current and future value stream maps, utilizing waterfall charts and pie/bar charts to illustrate value-added and non-value-added processes. The study identifies areas of waste and inefficiency, proposing strategies for waste reduction, standardization, and the implementation of techniques such as TAKT time, 5S methodology, Total Productive Maintenance (TPM), Overall Equipment Effectiveness (OEE), and Single Minute Exchange of Dies (SMED). The project explores methods for generating smaller batches, utilizing CNC machines, and implementing work cells to optimize process times. Benefits of these changes, including the use of Kanban, are discussed, and recommendations for factory layout, work cell design, and process improvements are provided. A comparison of current and future value streams, along with discussions on Six Sigma, Kaizen, and measuring improvements, concludes the analysis. The assignment aims to provide a detailed roadmap for Acme Machining to enhance efficiency, reduce costs, and meet increasing customer demands.

LEAN MANUFACTURING
Name
Number
Module Convener: Name

Contents
List of Figures..............................................................................................................................................4
List of Tables...............................................................................................................................................4
1) Introduction.........................................................................................................................................6
2) Current Value Stream Map..............................................................................................................7
3) Current Value Stream.......................................................................................................................8
Chart for water fall showing value added as well as non-value added processes...................................8
Pie chart showing non-value added and value added percentages.......................................................12
Bar chart showing non-value added and value added percentages......................................................12
Stream Map for Future Value................................................................................................................13
Chart for Water Fall with Non-value added and Future value Processes..............................................14
Pie chart showing non value added and value added percentages.......................................................18
Bar chart showing value added and non-value added per process.......................................................18
Discussion..................................................................................................................................................19
Waste reduction....................................................................................................................................19
Standardization.....................................................................................................................................19
TAKT time..............................................................................................................................................19
Types waste...........................................................................................................................................20
Promoting changes for immediate execution........................................................................................21
The use of 5-Ss approach.......................................................................................................................21
Total Productive Maintenance, TPM.....................................................................................................25
Overall Equipment Effectiveness, OEE...................................................................................................25
Single Minute Exchanges of Dies, SMED................................................................................................29
Methods............................................................................................................................................30
Generating Smaller Batches...............................................................................................................30
CNC Machines for attaining SMED.....................................................................................................31
Work Cells to lower Processes Time..................................................................................................31
Benefits..............................................................................................................................................32
Kan Ban..............................................................................................................................................32
Recommendations.....................................................................................................................................33
Work Cell...............................................................................................................................................33
Factory Layout.......................................................................................................................................34

Comparison of the current and future stream value.............................................................................34
Current stream value.........................................................................................................................34
Future Stream value..........................................................................................................................35
5S: Sort, Set in order, Shine, Standardize, Sustain.............................................................................35
Six Sigma............................................................................................................................................35
Kaizen................................................................................................................................................36
SMED.................................................................................................................................................36
Kanban...............................................................................................................................................37
Measuring improvements.....................................................................................................................37

List of Figures
Figure 1 Current Value Added Processes__________________________________________________________6
Figure 2 Current Cumulative Value Added Processes________________________________________________7
Figure 3 Current Non-Value Added Processes______________________________________________________8
Figure 4 Current Cumulative Non- Value added processes____________________________________________9
Figure 5 Pie Chart displaying value added & non-value added percentages for current____________________10
Figure 6 Bar chart displaying value added & non-value added per process for current_____________________10
Figure 7 Future Value Added Processes_________________________________________________________12
Figure 8 Future Cumulative Value Added Processes________________________________________________13
Figure 9 Future Non-Value Added Processes_____________________________________________________14
Figure 10 Future Cumulative Non-Value Added Processes___________________________________________15
Figure 11 Pie Chart displaying value added & non-value added percentages for future____________________16
Figure 12 Bar chart displaying value added & non-value added per process_____________________________16
Figure 15 New Factory Layout_________________________________________________________________27
List of Tables
Table 1 Value Added Processes for current VSM___________________________________________________6
Table 2 Value Added Processes for current VSM Cumulative__________________________________________7
Table 3 Non-Value Added Processes for current VSM________________________________________________8
Table 4 Non-Value Added Processes for current VSM Cumulative______________________________________9
Table 5 Value Added Processes for Future VSM___________________________________________________12
Table 6 Value Added Processes for future VSM Cumulative__________________________________________13
Table 7 Non-Value Added Processes for Future VSM_______________________________________________14
Table 8 Non- Value Added Processes for future VSM Cumulative_____________________________________15

1) Introduction
Acme Machining Company produces numerous parts for vehicles assembly plants. They have
existing operating costs of £50-100 p per hour. This is a case study regarding a single product
family, a vehicle disc brake in two kinds: for the near side as well as for the offside for a vehicle
built with custom. Chris Car Custom Vehicle assembly plant who is the customer needs such
components. The Chris Car Company has proposes they will be seeking to raise the orders they
make every month owing to the demand in the market (double current output).
The report is about if Acme Machine would be responsive or not.

2) Current Value Stream Map

3) Current Value Stream
Chart for water fall showing value added as well as non-value added processes
Table 1: VSM Value Added Processes
Value Added Processes for current VSM
Processes Base Fal
l
Rise Added Value (Min)
Drill 0 8 8
Turn 1 8 0 5 5
Turn 2 13 0 5 5
Grind 1 18 0 10 10
Grind 2 28 0 15 15
Turn 3 43 0 4 4
Inspect 1 47 0 7 7
Mask 54 0 15 15
Inspect 2 69 0 3 3
Paint 72 0 12 12
Final Inspection 84 0 6 6
Total Added Value 0 0 90 90
Drill
Turn 1
Turn 2
Grind 1
Grind 2
Turn 3
Inspect 1
Mask
Inspect 2
Paint
Final Inspection
Total Added Value
0
20
40
60
80
100
Current Value Added Processes
Processes
Time (Min)
Figure 1: Value Added Processes

Table 2: Current VSM Cumulative Value Added Processes
Value Added Processes for current VSM Cumulative
Process Added Value
(Min)
Added Value Cumulative(Min)
Drill 8 8
Turn 1 5 13
Turn 2 5 18
Grind 1 10 28
Grind 2 15 43
Turn 3 4 47
Inspect 1 7 54
Mask 15 69
Inspect 2 3 72
Paint 12 84
Final
Inspection
6 90
1 2 3 4 5 6 7 8 9 10 11 12
0
0.5
1
1.5
2
Current Cumulative Value
Added Processes
Drill Turn 1 Turn 2 Grind 1
Grind 2 Turn 3 Inspect 1 Mask
Inspect 2 Paint Final Inspection Total
Processes
Time (Hours)
Figure 2: Value Added Processes for Current Cumulative

Current VSM Non-Value Added Processes
Non-Value Added Processes for current VSM
Processes Base Fal
l
Rise Non- Value added
(Hrs.)
Drill 0 720 720
Turn 1 720 0 12.8 12.8
Turn 2 732.
8
0 17.5 17.5
Grind 1 750.
3
0 70.8 70.8
Grind 2 821.
1
0 112.
5
112.5
Turn 3 933.
6
0 7.9 7.9
Inspect 1 941.
5
0 18 18
Mask 959.
5
0 6.7 6.7
Inspect 2 966.
2
0 3.6 3.6
Paint 969.
8
0 8 8
Final Inspection 977.
8
0 6.3 6.3
Total Added
Value
0 0 984.
1
984.1

Drill
Turn 1
Turn 2
Grind 1
Grind 2
Turn 3
Inspect 1
Mask
Inspect 2
Paint
Final Inspection
Total Added Value
0
200
400
600
800
1000
1200
Current Non-Value Added Processes
Processes
Time (Hours)
Figure 3: Prevailing Non-Value Added Processes
Table 4: Current VSM Processes for Non-Value Added Processes
Non-Value Added Processes for current VSM Cumulative
Process NON - Value Added
(Hours)
Non-Value Added
Cumulative(Hours)
Drill 720 720
Turn 1 12.8 732.8
Turn 2 17.5 750.3
Grind 1 70.8 821.1
Grind 2 112.5 933.6
Turn 3 7.9 941.5
Inspect 1 18 959.5
Mask 6.7 966.2
Inspect 2 3.6 969.8
Paint 8 977.8
Final
Inspection
6.3 984.1

1 2 3 4 5 6 7 8 9 10 11 12
0
200
400
600
800
1000
1200
Current Cumulative Non- Value added processes
Drill Turn 1 Turn 2 Grind 1 Grind 2 Turn 3
Inspect 1 Mask Inspect 2 Paint Final Inspection Total
Processes
Time (Hours)
Figure 4: Non-Value Added Processes for Current Cumulative
Pie chart showing non-value added and value added percentages
0.998
0.002
Cur rent Str eam Map
Non- Value Added Value Added
Figure 5: Pie chart showing current non-value added & value added percentages