Project Poster - Lean Manufacturing
1
SZS IMPLEMENTING LEAN MANUFACTURING PRINCIPLES AT A MANUFACTURING COMPANY DEPARTMENT OF INDUSTRIAL & MANUFACTURING ENGINEERING SHOAIB IQBAL, MUFAZZAL, FAISAL NAJM, SALMAN AHMED JILANI Batch 2009-2010 LEAN MANUFACTURING A comprehensive set of techniques that, when united together, will allow the reduction and then elimination of the seven wastes: SZS, a private sector ISO 9001:2000 certified organization, is engaged in different domains as sighted below: S. Zia ul Haq & Sons Catering Portable Cabins Camp Management Services Manpower Supply Civil Engineering HVAC 1. Waiting 2. Over Production 3. Rejects 4. Excess Motion Specify what creates value Identify all the steps along the process chain Make those processes flow Make only what is pulled by the customer Go for precision by repeatedly removing wastes Implementing Lean Manufacturing Principles Reduction of Wastes & Productivity Improvement Through improving operations Through making Improvements in the design Through making enhancements in the Layout BASE-FRAME DESIGN OPTIMIZATION PRINCIPLES OF LEAN MANUFACTURING S. ZIA UL HAQ & SONS PROJECT DELIVERABLES WASTE ANALYSIS 0 20 40 60 80 100 120 Wastes Frequency Roof Frames fabricated at the ground TOOLS UTILIZED Material pre-cut at the store Specialized Workers for major operations LAYOUT ANALYSIS & ENHANCEMENTS 2 3 Pulley Mechanism 7 4 1 Retractable Awning 8 Proposed Design of Cart 6 Towing Car for transportation 5 Fixtures and Clamps 9 Pneumatic Riveter 12 Dr. M. Fahad (Associate Professor) Ms. Rabia Zubair (Lecturer) Mr. Azhar Qadri (Manager Engineering, SZS) Internal Advisors: External Advisor: Equipment On-spot Sizing Inappropriate Cart Height Fabrication at altitude Work overload Manual Material Lifting Exposed Manufacturing Floors Environment Waste Time & Resources Large distance between work and storage area Manual Riveting Manual Material Transfer Transportation Operations Current Design and Analysis of Base frame Proposed Designs of Base frame Proposed solutions for reduction of wastes Base Frame Design Optimization: Waste Analysis & Elimination: Layout Designing & Improvement: NX 7.5, ANSYS v14 WBS Time & Motion Study Quality Tools Kaizen 5S AutoCAD 2010 5. Over Processing 6. Excess Inventory 7. Transportation Current Layout of Manufacturing yards Current Proposed Distance 310.5 meters ~ 240 meters Time 3.33 hours ~ 2 hours Proposed Layout of Manufacturing yards 0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% % Reduction Results Design 1 Design 3 Design 2 Results Results
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Transcript of Project Poster - Lean Manufacturing
BASE-FRAME DESIGN OPTIMIZATION
BASE-FRAME DESIGN OPTIMIZATION
BASE-FRAME DESIGN OPTIMIZATION
PROJECT DELIVERABLES
PROJECT DELIVERABLES
S. ZIA UL HAQ & SONS
PRINCIPLES OF LEAN MANUFACTURING
LEAN MANUFACTURING
SZSIMPLEMENTING LEAN MANUFACTURING
PRINCIPLES AT A MANUFACTURING COMPANYDEPARTMENT OF INDUSTRIAL & MANUFACTURING ENGINEERING
SHOAIB IQBAL, MUFAZZAL, FAISAL NAJM, SALMAN AHMED JILANI
Batch 2009-2010
LEAN MANUFACTURING
A comprehensive set of techniques that, when united together,
will allow the reduction and then elimination of the seven
wastes:
SZS, a private sector ISO 9001:2000 certified organization, is
engaged in different domains as sighted below:
S. Z
ia u
l Haq
& S
on
s
Catering
Portable Cabins
Camp Management Services
Manpower Supply
Civil Engineering
HVAC
1. Waiting
2. Over Production
3. Rejects
4. Excess Motion
Specify what creates value
Identify all the steps along the process chain
Make those processes flow
Make only what is pulled by the customer
Go for precision by repeatedly removing wastes
Imp
lem
enti
ng L
ean
Ma
nufa
ctu
ring
Pri
ncip
les
Reduction of Wastes & Productivity
Improvement
Through improving operations
Through making Improvements in the
design
Through making enhancements in the
Layout
BASE-FRAME DESIGN OPTIMIZATION
PRINCIPLES OF LEAN MANUFACTURING
S. ZIA UL HAQ & SONS
PROJECT DELIVERABLES
WASTE ANALYSIS
0
20
40
60
80
100
120
Wastes
Frequency
Roof Frames fabricated
at the ground
TOOLS UTILIZED
Material pre-cut
at the store
Specialized Workers for
major operations
LAYOUT ANALYSIS & ENHANCEMENTS
2
3 Pulley
Mechanism
7
4
1 Retractable Awning
8 Proposed Design of Cart
6 Towing Car for transportation
5 Fixtures and Clamps
9 Pneumatic Riveter
12
Dr. M. Fahad (Associate Professor)
Ms. Rabia Zubair (Lecturer)
Mr. Azhar Qadri
(Manager Engineering, SZS)
Internal Advisors:
External Advisor:
Equipment
On-spot
Sizing
Inappropriate
Cart Height
Fabrication at
altitude
Work overload
Manual Material
Lifting
Exposed
Manufacturing
Floors
Environment
WasteTime &
Resources
Large distance
between work and
storage area
Manual
Riveting
Manual Material
Transfer
Transportation Operations
Current Design and Analysis of Base frame
Proposed Designs of Base frame
Proposed solutions for reduction of wastes
Base Frame Design Optimization:
Waste Analysis & Elimination:
Layout Designing & Improvement:
NX 7.5, ANSYS v14
WBSTime & Motion StudyQuality ToolsKaizen5S
AutoCAD 2010
5. Over Processing
6. Excess Inventory
7. Transportation
Current Layout of Manufacturing yards
Current Proposed
Distance 310.5 meters ~ 240 meters
Time 3.33 hours ~ 2 hours
Proposed Layout of Manufacturing yards
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
% R
edu
ctio
n
Results
Design 1 Design 3Design 2
Results
Results
