PACK-IT SOLUTIONS
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PACK-IT SOLUTIONS
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TQM 673 projects:
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Assignment #0-b Short summaries of the Lean Manufacturing & Six Sigma oriented movies Kamil Dzwonkowski IE673 - Fall 2008 - In class section September 29th 2008 eLearning ID # - Fall 2008-70-38 1) Mini Quality movie The movie is a summary of the Mini Cooper car diagnostics done by a group of engineers from BMW team. It points out the main characteristics of accuracy, precision and perfection need in an assembly processes. First, the points of car body joints are strictly taken under consideration. The points that are most exposed to external forces, and are the key joint points in the car body structure are being identified. That insure that the least amount of welding points is applied to the overall structure, therefore least material, time and cost is used, further the most efficient stability of the body is achieved. The body of the car is design to be useful as a platform for left and right side driver requirements; this is another example where lean manufacturing comes into play. This tactic makes the product universal and gives bases to have one plant assembly to supply a number of costumers of different needs. The prototype car tested in the BMW diagnostic facility is a reference point to the assembly production. During the production process each variables in each car are constantly measured, and strictly regulated to quality standards. This Six Sigma processes and other Lean manufacturing strategies result in a very high quality of the car, with a minimal cost. 2) Safety Integrated Process Automation for Chemical & Pharmaceutical Plants The automation system designed by Siemens for process control is a top of the line monitoring system for chemical and pharmaceutical industries. The system is equipped in a DCS controller that enables constant flow accuracy in the pre-set standards. It monitors temperature, pressure and speed of flow. The design of the system is safety oriented, with the focus on lean manufacturing. It provides the most output, by eliminating useless inputs. It’s implemented to minimize the need for shut down, and delivers years of undisturbed usage. The automatic system is able to detect small defects, as well as predict big explosions before they accrue. It could not only save human lives, but acknowledge of problems before they happen. This characteristic is a clear example of Lean thinking. The design is implemented with a backup constant flow circuitry (a ring), that provides feedback in a case of equipment failure. Using the ring strategy insures Six Sigma high quality maximized value of product. The valves implemented in the system has an ability to process partial stroke tests, which eliminate the need to shout down the flaw for testing procedures, improving this way the overall up time. Another features of the system is to use back up energy sources, that will result in process up time in case of black outs. Additionally, the system is simulated on a software version, where variables can be analyzed. Any changes in the model could be changed remotely form a distance. Concluding, we can see that the chemical plant monitoring, steering process is safety oriented and focused on Lean Manufacturing. While using the system we can minimize the spending in a number of plant sections, furthermore achieve higher output, with required quality. 3) Ford Rouge Assembly movie This movie is a summary of a truck assembly line. The core base for the assembly line in terms of Lean manufacturing is the use of scheduling to car parts strategies. The line has its parts in sequence to the production line. Even though each engine is different, so is the doors, and car equipment, all parts are parallel to each other during the assembly process. This tactic enables to result in the ability to produce a verity of models in one plant. Further, it saves space and profits in no over stock. Keeping the inventory adequate to the demand results in space, energy, product and man power cost savings. This is an example of where Six Sigma is constantly at play. The automated system of rotating the vehicle platform 180 degrees, profits the assembly technicians to work time, and quantity efficient with constantly keeping the quality high. Other features that provide high quality to the final product are usage of mechanical machines, to support the assembly technicians, that is for instance the mechanics that install the car doors with the help of pneumatically machinery. To test for any inconveniences with of the final product, the finished car is send to the Customer Acceptance Line, where it’s checked and approved by the future potential client. This even further insures high quality finished product. |
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