7ENT1128 Lean Manufacturing And Services Assignment-Hertfordshire University UK.

Module Code :- 7ENT1128
Module Title :- Lean Manufacturing and Services
Assignment Briefing :-
SCENARIO: You need to design the assembly line and warehouse layout for the Tesla Model 3 rear brake hub knuckle and suspension. Assume that the facility is separate from the rest of the Tesla factory and that the parts will be delivered to the facility (see appendix 1) and after being assembled be shipped to the Tesla factory.
7ENT1128 Lean Manufacturing And Services Assignment-Hertfordshire University UK.

7ENT1128 Lean Manufacturing And Services Assignment

Part of your consideration is that you will need to hire a building to do this and you need to design a layout before selecting an appropriate building. You are considering a number of square buildings of different sizes available to you and you wish to hire the smallest building possible to minimize on rent heating lighting and other costs. Both the assembly line and the warehouse layout need to be in the same building separated by a STRAIGHT wall. More over you also need to consider the ongoing costs of running your forklift truck(s) inside the plant.

Thus for this assignment you are to design the assembly line layout and adjoining warehouse layout as well as each work station’s layout (according to the demand stated below) for a Tesla model 3’s rear axle assembly for the parts shown in appendix 1, based on a demand for parts for 200 vehicles a day.

For this process, assume that:
Stations 1, 2 & 3A & 3B (represented below) assemble their sub-assemblies in parallel at the same rate which are combined at station 4. Completed assembles are then transported to the warehouse.

7ENT1128Lean Manufacturing And Services Assignment

Your aim is to design a layout can accommodate your process that:
♦ Has the smallest overall size
♦ Minimises operator walking
♦ Minimises distance travelled by forklift trucks which carry the pallets

7ENT1128 Lean Manufacturing And Services Assignment-Hertfordshire University UK.

Your submission should consist of the following:
Part 1 – Layout Drawing – PDF Document
Part 2 – Part B – Logic and Theory Behind the design 1x PowerPoint (.ppt or .pptx file) OR a pdf document

Part 1 – Layout Drawing – PDF Document
Using either:
♦ a CAD package of your choice
♦ the spreadsheet template provided where each square cell represents 1mx1m Generate a dimensionally accurate layout of the building, showing the following:

A) The layout of the assembly line, showing the following:
♦ Assembly station locations,
♦ Assembly station part storage, Assume that “boxes” are stored on the workbench.
♦ The forklift truck movement needed for material flow.
♦ WIP (or Kanban) areas between stations as appropriate:
♦ If stations 1, 2 or 3A or 3B are alongside station 4 provide a WIP area for a shelf for each subassembly of 1x1m.
♦ If stations 1, 2 or 3 are more than a few steps away, assume that you have trolleys (1x1m) which workers manually push to the next station. Assume you’ll need 3 trolleys per subassembly for this purpose.
♦ Assume each trolley / shelf has a capacity of 4 subassemblies.

7ENT1128 Lean Manufacturing And Services Assignment-Hertfordshire University UK.

It is not necessary to show the detailed layout of the actual assembly stations simply in dicate its foot print. You should arrange your part storage around these areas allowing for convenient access i.e. minimum walking to the parts and the workstations by the assembly workers.

7ENT1128 Lean Manufacturing And Services Assignment-Hertfordshire University UK.

B) The layout of the warehouse with appropriately sized areas for each part, assuming:
♦ Maximum of one delivery of parts each week Mon Friday assume that each delivery for a part might be on ANY day of the week and might vary from one week to the next.
Also assume different parts might be delivered on different days.
♦ ONE shipment of completed assembles leaves the facility each day at the end of the shift.
♦ Left and right completed assemblies can be packed into identical stillages inter changeably.

C) You will need to develop a strategy for transporting PARTS ON PALLETS ONLY On your drawing show the precise route of travel of your transporter for each part assembly empty pallet being transported.

On your layout show each route of travel in a different colour as appropriate and label the route of Ttravel.

Assume that for each pallet of PARTS the forklift needs to:
♦ move the pallet from the delivery truck bay to its location in the warehouse As required:
♦ collect the part from the warehouse
♦ deliver to the assembly line
♦ dispose of empty pallet in the warehouse.

Part 2 – Logic and Theory Behind the design and outcome.
This should consist of 2 parts:
A. In this section you have the opportunity to explain to the markers the logic and theory you’ve used in creating your design for example how you have end eavoured to minimise Ohno’s wastes.
B. Calculate the monthly distance travelled by the forklift truck s which transport parts on pallets You can ignore transportation on small parts in boxes Show your as sumptions and calculations Suggestion use a spread sheet.
C. State the overall minimum size of the layout you have designed.

You have a choice on how to submit this:

♦ As a narrated PowerPoint presentation – maximum 5 minutes
♦ As a PDF file – Maximum ONE A4 page explanation (Arial font size 12) and Maximum TWO A4 pages calculations  spread sheet printout. Total Three pages Max.
This will be marked alongside your drawing from Part 1, so you do not need to redraw parts of your drawing. Simply refer to clearly labelled points on your drawing as needed.

7ENT1128 Lean Manufacturing And Services Assignment-Hertfordshire University UK.

General Notes Requirements and Constraints:
1. In the ware house show each location for parts as an appropriately dimensioned and labelled area.
2. In the warehouse show the location for completed assemblies in appropriately sized & dimensioned area.
3. Provide an area 20% larger than one day’s production for completed assemblies in the ware house where they will await shipping
4. Provide transportation for the completed assemblies from the final station to the ware house.
5. Assume that loaded pallets can NOT be stacked. Assume that boxes can be stacked put on shelves 2 boxes high.
6. Aisles should be a minimum of 3m wide to allow for forklift access.
7. Assume that for security reasons you wish to keep the ware house area separate but ad joining to assembly area with a 4m wide doorway in a STRAIGHT wall that separates them. The position of the door way can be any where a long this wall.
8. Assume that the warehouse area has a loading unloading area adjoining the street where delivery vans  small lorries can reverse into of 5m wide x12m long
9. Assume that the foot print of each pallet is 1m x 1m
10. Assume that empty pallets can be stacked up to 10 pallets high provide an area for empty pallets in the ware house assuming that they are cleared after the end of each shift. This is done by an external contractor who will using their own equipment move the pallets from this storage area in the warehouse to the loading/offloading bay.
11. Assume that boxes pallets are unpacked by the operator directly at the assembly
12. Clearly show the outside boundary of your area needed as a thick dashed line.
It is not necessary to draw details of the actual potential building
13. It is not necessary to make provision for rest areas/toilets office space. Assume that these are catered for on a raised area which you do not have to draw.
14. Assume that completed assemblies are placed on stillages. Assume that TWELVE completed assembles can be placed on each stillage at station 4. Assume that the stillages for this similar to the one below dimensions 1mx2m are recycled on an on going basis bet ween your assembly operation and Tesla. At the end of each shift all the full stillages are shipped to Tesla and replaced with empty ones ready for the next day.

7ENT1128 Lean Manufacturing And Services Assignment-Hertfordshire University UK.

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