Semester 2 2016-17 Continuous Assessment Assignment No 2 The company DITDisc have engaged you as a Lean consultant and asked you to propose the staged implementation of a Lean environment for them. Your job is to examine the current system and design a Lean Manufacturing System. At this time, the company are not focused on re-designing their existing machines so for now, you can assume they remain as they are and that additional equipment will not be purchased. Background Please read the Case Study text to familiarise yourself with the company, the product the process and the core management systems. In conjunction with the case study, please use the excel spreadsheet provided (outlining current capacity, inventory and demand information) to assist you in considering the following questions Questions 1. Draw a value stream for the manufacture of a disc (flat PVC to seal). Value stream mapping software is available within Quality Companion. (20 marks) 2. Based on VSM Analysis, comment on your key findings and the Lean opportunities which are apparent. (4 marks) 3. Justify your decision as to whether the floppy disc manufacturing plant would be best to build to demand or to a finished goods supermarket. (4 marks) 4. Lean theory suggests that Lean Systems are often designed around specific product families. Explain how this concept can be applied in this plant (4 marks) 5. Propose the constituents of one efficient “Lean cell” for this plant. By constituents, I mean the processes involved in such a cell, number of machines per process in the cell, the number of direct operators per cell per shift and the role of each operator. (15 marks) 6. In relation to your proposed cell, answer the following (i) What would be the capacity of the cell per 24 hours, what single point would be scheduled and what consistent increment of work would you propose to release and withdraw from your cell? (5 marks) (ii) Between what processes would you introduce Kanban pull? Explain the type or types of Kanban you would use and in practical terms in each case, explain how they would operate (e.g. what is the Kanban signal to the operator, kanban size, control of material flows) (8 marks) (iii) Explain the key considerations that came into play in determining the Kanban sizes (5 marks) (iv) In trying to keep products flowing in a Lean cellular format, are there any particular problematic processes evident? If so, explain the problem in relation to the process(es) and propose a suitable way to ensure it features in your Lean system? (5 marks) (v) Sketch a layout of your proposed cell (5 marks) 7. Draw a future state map of your proposed cell and explain its benefits (compared to the current state) (10 marks) 8. How many Lean Cells in total would you propose for the plant? Justify the number of proposed cells (5 marks) 9. The Quality and Maintenance departments are support services to Manufacturing Departments currently. Consider and justify the way in which you would best integrate these people into the Lean structure and propose the steps involved in managing that transition (5 marks) 10. What key HR issues (if any) do you see as needing to be addressed as you roll out a Lena structure in the plant. Propose how these might be best addressed. (5 marks)