INDU 321: Lean Manufacturing Case Study - Industrial Engineering Assignment Help

Assignment Task:

Project Case – STRAT 
STRAT is supplying flaps (aerostructure components, shown in Figure 1) to a major airplane manufacturer Airpro. STRAT has high levels of WIP inventories and have to expedite orders or work overtime to meet the monthly demand target. The company is facing high costs, late deliveries and has long lead times. To stay competitive, they must reduce unnecessary overtime, reduce lead time and costs and deliver to their customer on time. 

Figure 1. Flap 
Product structure and the production environment: 
STRAT ships flaps to Airpro once a week. Flaps are sold in pairs called shipsets and each shipset contains on left and one right flap. Each flap is made up of 2 main components; Lower Cover and Upper Cover. Each Cover is made up of a Noodle, Skin, and Stringer. See Figure 2 for the product structure diagram. 

Flap 
Upper cover Lower Cover 
Stringer Noodle Skin Stringer Skin Noodle 
Figure 2. Flap structure diagram 
Customer demand: 
STRAT has to deliver 8 shipsets to Airpro each month (two shipsets in each week). 
Production control department: The department performs the following actions: 
• Receives (by Fax) 2-month forecast from Airpro and enters it into SAP. 
• Receives (by Fax) weekly order from Airpro, 
• Sends (by Fax) the 2-month forecast to the raw material suppliers, Complast, 
• Sends (by Fax) weekly orders to Complast, and replenishes raw material by a weekly order, 
• Generates MRP- based weekly requirements and issues daily updates, 
• Sends printed operations schedules to all the departments. 
Production processes: 
The sequence of required production processes are identified in Figure 3: 
Figure 3. Flow diagram 
The company currently operates 5 days a week. Each shift is 8 hours and there are 2x15min paid breaks and 30min paid lunch in each shift. Company has been considering adding more work shifts to satisfy the demand however, the final decision is pending the outcome of your analysis. Reasonable overtime is allowed. 
The following table shows the specific process requirements and other pertinent information:

Process Name Observed Inventory Skin (Raw material) 7 units Stringer (Raw material) 6 units Noodle (Raw material) 9 units ATL 5 units PLY Cut 6 units HDF 4 units Noodle Manufacturing 10 units 
Cover Assembly 7 units 
0.98 
3/4 
Flap Assembly 7 units Autoclave 6 units 
You are requested to improve STRAT’s operations by designing a lean value stream for their selected flaps product family. 
a) Use all the tools/techniques you have learned in this course and be as detailed as 
possible to propose a lean flow. Elements of your design should include: 
• Finished goods strategy, continuous flow cell(s)/Pacemaker, staffing and machine requirements, operator work distribution, load and mix levelling, weekly schedules (how will the production employees know what to work on next?), required supermarket, FIFO size (if any), etc.), 
• For batch processes (if any), production lot size and trigger points, 
• List of improvements to be made to achieve the proposed future state. 
b) Identify the following improvements (if any) you’ve made by implementing lean: 

c) If the demand is increased by 1 shipset per month and is expected to stay at this level in the foreseeable future, explain what kind of impact this will have on your production system and how you will cope with this increase. Be brief but specific in your recommendations. 

This Industrial Engineering Assignment has been solved by our Industrial Engineering Experts at My Uni Paper. Our Assignment Writing Experts are efficient to provide a fresh solution to this question. We are serving more than 10000+ Students in Australia, UK & US by helping them to score HD in their academics. Our Experts are well trained to follow all marking rubrics & referencing style.

Be it a used or new solution, the quality of the work submitted by our assignment experts remains unhampered. You may continue to expect the same or even better quality with the used and new assignment solution files respectively. There’s one thing to be noticed that you could choose one between the two and acquire an HD either way. You could choose a new assignment solution file to get yourself an exclusive, plagiarism (with free Turnitin file), expert quality assignment or order an old solution file that was considered worthy of the highest distinction.