As the consultant for KU Consulting, you have been authorized to change the existing facility (limited construction budget) and/or refine the process flow of the manufacturing area. Operational limitations: All changes must be completed within a 60 day window with the majority of the changes happening at night when the plant is idle or on the weekend when the plant is idle.
(a) List and detail a minimum of five proposed changes and/or alterations. For each proposed change provide rationale to fully and thoroughly substantiate why you chose that particular change, how the change will take place, and be accomplished within the operational limitations.
(01)
(02)
(03)
(04)
(05)
Introduction
Question One
Refer back to your answers in Assignment #3 and Assignment #6. Select four of the challenges listed in the assignment instructions. For each of the challenges selected identify specific and detailed recommendations related to each challenge to assist and improve Albatross Anchor.
Challenge #1:
Challenge #2:
Challenge #3:
Challenge #4:
(b) List and detail three implications and three complications that may occur as a result of the changes recommended in (a) above. Remember activities in one area of the facility may have an impact on other areas of the facility.
(01)
(02)
(03)
(c) Create a Gantt chart showing a timeline for when the different changes proposed should be made, detailing which changes may overlap and showing how long each change will take to institute. Provide information to support your decisions and to explain your choices as shown in the Gantt chart.
(01) Gantt Chart
(02) Explanation of the Gantt Chart.
Conclusion
(a) Proposed changes and/or alterations:
(01) Install additional lighting in the manufacturing area: This proposed change aims to improve visibility and safety in the manufacturing area during night shifts or weekends. It can be accomplished by hiring an electrician to install the necessary lighting fixtures and wiring, which can be scheduled during idle periods of the plant.
(02) Implement a lean manufacturing process: This change will involve analyzing the current process flow and identifying areas of waste or inefficiency. By implementing lean principles, such as reducing unnecessary movements and optimizing production flows, the manufacturing area can become more streamlined. Training sessions can be conducted during idle periods, and the implementation can be done in phases to minimize disruptions.
(03) Install automated assembly equipment: By introducing automated assembly equipment, the manufacturing process can be made more efficient and reduce the reliance on manual labor. This change can be implemented during idle periods by coordinating with the equipment supplier for installation and training the staff on operating the new equipment.
(04) Reconfigure the layout of the manufacturing area: This change involves rearranging the equipment and workstations in the manufacturing area to optimize the flow of materials and minimize unnecessary movements. The reconfiguration can be done during weekends or nights, when the plant is idle, by coordinating with maintenance personnel and following a detailed plan to ensure minimal disruption to the production schedule.
(05) Implement a preventive maintenance program: This proposed change aims to reduce downtime due to equipment breakdowns. By implementing a preventive maintenance program, regular inspections and maintenance can be scheduled during idle periods, ensuring that equipment is in optimal condition and minimizing unexpected disruptions during production.
(b) Implications and complications:
(01) Implication: The installation of additional lighting may require electrical work, which could potentially disrupt other areas of the facility that share the same electrical infrastructure. Complication: To mitigate this, a thorough assessment of the electrical system should be conducted beforehand, and necessary measures should be taken to avoid any power outages or electrical disruptions.
(02) Implication: Implementing a lean manufacturing process may require changes in work routines and employee training, which can initially slow down the production output. Complication: To address this, proper training and communication with the employees should be carried out to ensure their cooperation and understanding of the benefits of the new process. Implementation can be gradual to minimize disruptions.
(03) Implication: The installation of automated assembly equipment may require modifications to the existing infrastructure or workstations, which might impact other areas of the facility. Complication: Close coordination with the equipment supplier and thorough planning should be done to minimize any disruptions and ensure that modifications or reconfigurations can be done efficiently without affecting other production processes.
(c) Gantt Chart:
(01) Gantt Chart:
Week 1-2: Assess lighting requirements and hire an electrician for installation.
Week 3-4: Install additional lighting fixtures.
Week 5-6: Conduct training sessions on lean manufacturing principles.
Week 7-8: Analyze current process flow and identify areas for improvement.
Week 9-14: Implement lean manufacturing changes in phases.
Week 15-18: Coordinate with equipment supplier for installation of automated assembly equipment.
Week 19-22: Conduct training sessions on operating the new equipment.
Week 23-26: Reconfigure the layout of the manufacturing area.
Week 27-30: Implement preventive maintenance program.
Week 31-60: Continuously monitor and improve processes.
(02) Explanation of the Gantt Chart: The Gantt chart outlines a timeline for the proposed changes, taking into consideration the operational limitations and potential overlaps between different tasks. The chart starts with assessing lighting requirements and hiring an electrician, followed by the installation process. Training sessions on lean manufacturing can be conducted simultaneously to start improving the process flow. Lean manufacturing changes will be implemented in phases to ensure a smooth transition. The installation of automated assembly equipment will be done later, followed by training sessions on operating the equipment. The reconfiguration of the layout will then be carried out, and finally, the preventive maintenance program will be implemented. The timeline allows for continuous monitoring and improvement of processes beyond the initial 60-day window.