This Assignment assesses the following module Learning Outcomes (from Definitive Module Document): LO1. Describe techniques associated with “lean” processes in various contexts including quality assurance. LO4. Apply principles and techniques associated with “lean” processes to existing or new processes. LO5. Incorporate a systems perspective to the holistic design of processes in their operational context. Assignment Tasks: You are to design a continuous assembly process for your LEGO kit (Kit1-Assembly.pdf Download Kit1-Assembly.pdf , Kit2-Assembly.pdf Download Kit2-Assembly.pdf , Kit3-Assembly.pdf Download Kit3-Assembly.pdf ) which has been provided for you (See appendices accompanying this document for basic build instructions and part lists for the kits). It is expected that you will improve on the very basic sequence of assembly provided. Your process must be designed to build 40 kits per hour – you will need to calculate how many operators this requires (use the minimum number of operators needed to achieve this). In this section, you are to calculate determine how many assembly operators you will need to build 40 kits per hour. To do this, you will need to measure, or estimate* the total build time for the model. (*if you prefer to estimate the build time it can be done using the standardised Predetermined Assembly times provided in Appendix I (click here to download) Download Appendix I (click here to download) . You may prefer to do this if you don’t have access to the kits for whatever reason). Section 2. Design of assembly process (30 Marks) – “Job Element Sheets” In this section, you are to design the work allocation for each station, defining the process and sequence in which your kit will be assembled. You are to specify the steps of each worker’s station using a “Job Element Sheet” (JES) (sometimes called a “Standardised work instruction”) on the template provided, or using your own template if you prefer. For each step, your Job element sheet should include: A numbered sequence for each step The time for the step A brief desсrіption of the step If needed, a photo or image to guide the step (Hint: Use your mobile phone set at LOW-RES to take photos) If a new part is added to the assembly: list the part number(s) (see Appendix 1) Be sure to include an appropriate rest allowance as the last item on your JES (template available Download template available ), which is to be based on your cycle time. Well-balanced processes will achieve higher marks. Jigs & Fixtures: you may assume that jigs and fixtures are available for your operations if needed. Section 3. Line Balancing and Capacity planning (25 Marks) Provide 3 subsections as follows: 3.1. Using a bar chart, show graphically the work allocation for each operator, with a bar representing each operator’s loading in seconds. Well-balanced processes will achieve higher marks. 3.2 Indicate the takt time for the overall assembly line. 3.3 Calculate the number of completed kits that your process would deliver (i.e. process capability) in a continuous 5-hour shift, assuming that you started with an empty line, with no WIP at the start of the shift. 3.4 You have been informed that the demand for LEGO kits is expected to double in the next 4 months. This sudden increase in the demand is not expect to last for a long period of time. What options does the company have to temporarily expand its capacity? Identify THREE viable solution and discuss them (10 marks). Part B – Industry 4.0 Poster (35 marks) In section B, you are to design a PowerPoint A3 poster on Industry 4.0 in which you will: 1. Describe three technologies that could be integrated into your production system to achieve a ″smart system″ and discuss their advantages. 2. Discuss how each technology could be integrated into the production system.
