continuous improvement application in vehicle assembly plant - project 2 report

5/22/2018 Continuous Improvement Application in Vehicle Assembly Plant - Project 2 Report

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King Saud University

College of Engineering

Department of Industrial Engineering

CONTINUOUS IMPROVEMENT APPLICATION

IN VEHICLE ASSEMBLY PLANT

By

ANMAR MILYANI

ABDULLAH ABU-TAYLI

SULTAN BIN-TAYYASH

Submitted in partial fulfillment of the requirement for the

degree of Bachelor of Science in Industrial Engineering

at the College of Engineering, King Saud University

Riyadh

1430 - 1431 H

(Semester 2)


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ABSTRACT

The project is focused on continuous improvement applications in truck

assembly plant in Jeddah. The plant is building Volvo trucks and currently deploying

Volvo Production System which is a variation of TPS. The purpose of the CI

application is to improve productivity and reducing manpower. This project is solving

the problem of data collection using visual management methods (Andon system)

which is a part of CI. The new approach is based on sensors, PBs and PLC to monitor

the time each truck stays in the workstation. The data is then analyzed and presented

in several LCD screen distributed in different locations of the production line. A

software tool based on theory of constraints will be constructed to identify the

bottlenecks of the production line based on the correct data from newly developed

data collection system. This step is very essential to the plant management to identify

where the CI activities would provide the best results.


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TABLE OF CONTENTS

CHAPTER 1: INTRODUCTION.......................................................................................... 71.1 AVI/VOLVO.................................................................................................................................71.2 PRODUCTIV ITY IMPROVEMENT..........................................................................................91.3 PROBLEM DEF INI TION..........................................................................................................9

CHAPTER 2: BACK GROUND.......................................................................................... 102.1 TOYOTA PRODUCTI ON SYSTEM (TPS)..............................................................................102.2 CONTINUOUS IMPROVEMENT ...........................................................................................112.3 THEORY OF CONSTRAI NT ...................................................................................................122.4 DATA COLLECTION ..............................................................................................................13

2.4.1 VISUAL MANAGEMENT............................................................................................... 132.4.1.1 ANDON SYSTEM.................................................................................................... 15

2.1.2 CONTROL MANAGEMENT........................................................................................... 172.1.2.1 PROGRAMMABLE LOGIC CONTROLLERS (PLC) ............................................ 172.4.2.2 SENSOR.................................................................................................................... 19

CHAPTER 3: PROBLEM DESCRIPTION....................................................................... 203.1 LAYOUT.....................................................................................................................................22

CHAPTER 4: SOLUTION METHODOLOGY................................................................. 274.1 SOLUTION COMPONENT......................................................................................................27

4.1.1 DATA COLLECTING DESIGN....................................................................................... 274.1.2 SENSORS.......................................................................................................................... 284.1.3 PUSH BUTTON AND SIGNAL LIGHT.......................................................................... 304.1.4 PLC AND DATA ANALYSIS.......................................................................................... 314.1.5 MONITORING.................................................................................................................. 31

4.2 FI NAL DESIGN........................................................................................................................334.3 ANALYSIS DATA USING VISUAL BASIC FOR APPLICATIONS (VBA)..........................36

CHAPTER 5: RESULTS AND DISCUSSION................................................................... 41CHAPTER 6: CONCLUSIONS AND RECOMMENDATIONS..................................... 42REFERENCE........................................................................................................................ 43


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LIST OF TABLE

Table 3. 1 : Sequence of stations in the plant.........................................................26

Table 4. 1 : Total cost and quantities.......................................................................35


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LIST OF FIGURE

Figure 1. 1: Volvo FM..................................................................................................8Figure 1. 2 : Volvo FH................................................................................................8Figure 2. 1 : Andon system........................................................................................16Figure 2. 2: visual screen in the plant.....................................................................17Figure 2. 3: screen is show status of plant..............................................................17Figure 2. 4: PLC box.................................................................................................18Figure 2. 5 : wires for PLC.......................................................................................18Figure 2. 6 : sensor laser...........................................................................................19Figure 3. 1: sample data from the plant...................................................................21Figure 3. 2 : show the layout of all stations..............................................................22Figure 3. 3 : :Station 1 chassis assembly..................................................................23Figure 3. 4: Station 2 turn chassis............................................................................23Figure 3. 5: Station 3 axles assembly......................................................................23Figure 3. 6 : Station 4 cables assembly.....................................................................24Figure 3. 7: Station 5 cables assembly on chassis....................................................24Figure 3. 8 : Station 6 radiator assembly.................................................................24Figure 3. 9: Station 7 engine assembly and gear box..............................................25Figure 3. 10: station 8 engine with gear on chassis.................................................25Figure 3. 11: station 9 radiator assembly on chassis..............................................25Figure 3. 12 : Station 10 tires assembly....................................................................26Figure 3. 13: Station 11 cab assembly......................................................................26Figure 3. 14 : final product........................................................................................26Figure 4. 1: sensor......................................................................................................28Figure 4. 2: top view for the station with sensors....................................................29Figure 4. 3: side view for the station with sensors..................................................29Figure 4. 4: Andon Light Visual Control System with Flashing Capability and

Alarm. .........................................................................................................................30Figure 4. 5: plc Siemens.............................................................................................31Figure 4. 7: install screen...........................................................................................32Figure 4. 6 : show the layout of all stations with monitor places...........................32Figure 4. 8 : Final design of management monitoring system................................34Figure 4. 9 : picture show model for program in VBA............................................37Figure 4. 10 : picure show basic form in program...................................................36Figure 4. 11: a bottleneck in the first station...........................................................38Figure 4. 12: A bottleneck in the last station...........................................................39Figure 4. 13: A bottleneck in two different stations................................................39Figure 4. 14 : A bottleneck at any station in the center...........................................40
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NOMENCLATURE

AVI: Arabian vehicles and trucks industry.

CI: Continuous improvement.

TPS: Toyota production system.

VPS: Volvo production system.

TOC: Theory of constraint.

VBA: Visual Basic for applications.

LCD: Liquid crystal display.

PLC: Programmable logic controllers.

ACKNOWLEDGMENT

We are appreciating the AVI factory for accommodation and their kindness

and helping us. Also for give us the data and information we needed.


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CHAPTER1:INTRODUCTION

This project is studying CI in production lines which help decision makers

reach their goals with minimal effort and time. The most important applications of CI

are found in increasing productivity and efficiency and eliminate unnecessary wastes,

which could delay production. The project is conducted with the direct coordination

with AVI in Jeddah where the goals and methodology were jointly determined.

1.1AVI/VOLVO

Automotive companies adopted the deployment of continuous improvement

principles, Volvo is not an exception. Volvo Truck is a leading company in industry

starting 1928. Volvo Trucks is one of the largest manufacturers of heavy trucks in the

world and continuing to play a leading role in the development of new vehicles and

transport solutions. In 1979, Volvo Trucks, which had sold trucks in Saudi Arabia

since 1962, strengthened its presence in the country by appointing Zahid Tractor its

exclusive distributor in the Kingdom. Through Zahid Tractors efforts in the market

place and continuous investment in facilities and services to support the Volvo brand,

Volvo trucks have become a fixture for roads and highways throughout the Kingdom.

In 1998, to meet the dynamic growth of Volvos truck sales in the Region,

Zahid Tractor and Volvo Trucks formed Arabian Vehicles and Trucks Industry (AVI).

A new ergonomically designed and tooled plant was built at Zahids Kilo 14 Complex

on the outskirts of Jeddah. The first Volvo FH truck rolled off the assembly line in the

autumn of 1999. AVI became ISO 9002 certified in April 2000, and re-certified to

ISO 9000:2000 as of April 2003.

The first assembly plant was established by Zahid tractors on 1988 under the

name (the Arabian vehicle ). The plant started with a production capacity of one truck

each three days and manpower of 15 employees. Today the producing 5 trucks per

day by manpower of more than 80 employees. The factory is consist of main

production line which depends on the type of the truck, administrative building,

quality room and check and includes a number of stations, which is about the

sequence and assembly of spare parts for trucks. The first station is assembly of the

chassis, the second station is assembly axles on the chassis, the third station is


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assembly and install electrical cables on the chassis and the fourth station is assembly

of the gears and engine on the chassis and the fifth station is assembly and installation

of the radiator. And the sixth station is to install wheels. The seventh station is

installed the cab on the truck, and then comes the stage of examination and testing by

computer.(2)

They are produce many type of truck as:

Volvo FM

The reliable workhorse in construction

and distributionCombination weight:

Up to 100 tones

Chassis height:810 to 1200 mm

Engines:D9B: 300, 340, 380 hp

D11B*: 390, 430 hp

D13A: 360, 400, 440, 480 hp

D13B: 360, 400, 440 hp* 4x2 and 6x2 tractors only. (5) Figure 1. 1: Volvo FM

Volvo FH

The champion on the long routes

Combination weight:Up to 100 tones

Engines:D13A: 400, 440, 480, 520 hp

D13B: 400, 440, 500 hp

Cabs:Day cab, Sleeper cab, Globetrotter,

Globetrotter XL. (5)

Figure 1. 2 : Volvo FH


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1.2PRODUCTIVITYIMPROVEMENT

After acquiring good knowledge of the problems which delay CI activities, the

group in this project decided to focus on improvements to increase production and

reduce wastes. The Visual management include andom system design was selected to

determine data input and output truck at station by sensors, The Theory of Constraints

methodology was selected to determine the exact location of the bottlenecks in the

assembly line. The results of the constraint analysis will be used to identify the causes

of the delay and accordingly use the appropriate continuous improvement technique

to reduce the wastes.

1.3PROBLEMDEFINITION

Providing AVI company with robust tool for constraints detection in the truck

assembly line as part of their continuous improvement activities. This will be

achieved through our visits to the factory and meetings with engineers and

management. It was noticeable that the plant is suffering from some problems that can

cause losses, for example: delay because of disruption of production at the factory.

The main problem is that the plant does not have tools that accurately identify the

location and the effects of the production disruption and dont have accurate data for

analysis so,converting main project from data analysis to collect data.


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CHAPTER2:BACKGROUND

In this chapter the topics that are relevant to the main topic of the project will

be explored. These topics are important in understanding the problem that we faced at

the factory and in providing engineering solutions for AVI Company. Since there is a

strong relationship between the Toyota Production System and the Volvo production

system (VPS), TPS was considered in this background study.

2.1TOYOTAPRODUCTIONSYSTEM(TPS)

Is an integrated socio-technical system,developed by Richard Bruce Phillips

that comprises its management philosophy and practices. The TPS organizes

manufacturing and logistics for the automobile manufacturer, including interaction

with suppliers and customers. The system is a major precursor of the more generic

"Lean manufacturing."Taiichi Ohno,Shigeo Shingo and Eiji Toyoda developed the

system between 1948 and 1975.

Toyota includes consistency comes from operational excellence. The

operational excellence is based on the quality improvement tools and methods

developed by Toyota (under the TPS): such as JIT, kaizen, one-piece-flow, jidoka,and heijunka. (1)

Evidence of excellence in the Toyota production system: Philosophy (Long-term thinking). Process (eliminate waste) Kaizen. People and partners (Respect, Challenge them to achieve more, Grow leaders). Problem-solving (Continuous improvement and learning) . Waste reduction is an effective way to increase profitability.
http://en.wikipedia.org/wiki/Socio-technical_systemshttp://en.wikipedia.org/wiki/Lean_manufacturinghttp://en.wikipedia.org/wiki/Taiichi_Ohnohttp://en.wikipedia.org/wiki/Shigeo_Shingohttp://en.wikipedia.org/wiki/Eiji_Toyodahttp://en.wikipedia.org/wiki/Eiji_Toyodahttp://en.wikipedia.org/wiki/Shigeo_Shingohttp://en.wikipedia.org/wiki/Taiichi_Ohnohttp://en.wikipedia.org/wiki/Lean_manufacturinghttp://en.wikipedia.org/wiki/Socio-technical_systems


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2.2CONTINUOUSIMPROVEMENT

Continuous improvement, in regard to organizational quality and performance,

focuses on improving customer satisfaction through continuous and incremental

improvements to processes, including by removing unnecessary activities and

variations.

The seeking of small improvements in processes and products, with the

objective of increasing quality and reducing waste. Continuous improvement is one of

the tools that underpin the philosophies of total quality management and lean

production. Through constant study and revision of processes, a better product can

result at reduced cost. Kaizen has become a foundation for many continuous

improvement strategies, and for many employees it is synonymous with continuous

improvement.

All work carried out can be improved. And all current process they must

contain no waste of any kind "whether material or moral or intellectual. And the

reduction of these waste results in a value-added of the process and the client benefits

from the results, and take advantage of that make Improvements in a Specified Time

Frame while Spreading Improvements throughout the plant and Promote Employee

Involvement, Teamwork and Creative Thinking. Achieve the required Cost Savings to

remain Competitive in the Market Place.

1. Increasing Productivity.2. Standardizing Cycle Times.3. Reducing Costs.4. Developing Leadership.5. Developing Teamwork.6. Reducing Defects.

Types of continuous improvement targets:

1- Quality2- Cost3- Delivery4- Safety5- Morale


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2.3THEORYOFCONSTRAINT

The Theory of Constraints (TOC) concepts to accelerate process improvement

in manufacturing and project operations. Theory of Constraints makes it possible for

companies to improve their operations far faster and to greater heights than any other

approach in the market today.

Definition:

The Theory of Constraints is a management philosophy that focuses the

resources of an organization on improving the performance of the constraint that

directly affects the P&L. It is an approach to solve constraints and problems in a

logical way by building a logic chart of the problem, finding its roots and developing

steps to remove the root of the problem. TOC methods are used by managers and

sales personal to improve the management and sales of their companies. (4)

Technique used in the knowledge of the delay in the production line is the

theory of constraints. The Theory of Constraints states that every system must have at

least one constraint limiting its output.

Include the main theme of the project because they follow the approach of

continuous improvement (reduction of operating expenses and inventory and increase

energy productivity) on the basis of five-steps we used in the analysis:

1. Identify the systems constraint(s).2. Decide how to exploit the systems constraint(s).3. Subordinate everything else to the decisions of Step 2.4. Elevate the systems constraint(s).5. If a constraint is broken in Step 4, go back to Step 1

It seeks to identify the company and the difficulties and obstacles to

productive use to the maximum extent possible, the inventory and operating costs to a

minimum.


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We need to define terms used in theory of constraint.Cycle time:the actual time it takes to perform a task and forward it to the next step.(3)

Throughput:The volume of production passing through the process over some timeperiod.

Throughput rate =1

Blocking:Occurs when the activities in a stage must stop because there is no place to

deposit the item just completed.

Starving:Occurs when the activities in a stage must stop because there is no work.

Bottleneck:is defining as the rate (parts per unit time) of the work station having the

highest long-term utilization.

2.4 DATACOLLECTION

2.4.1VISUALMANAGEMENT

Visual management is one of the lean techniques designed so that

anyone entering a work place, even those who are unfamiliar with the detail of the

processes, can very rapidly see what is going on, understand it and see what is under

control and what isnt. Essentially, the current status of the operation can be assessed,

at a glance.

o Visual management advantages Understand and indicate work priorities. See whether performance (usually daily) was met. Identify the flow of work and what is being done. Identify when something is going wrong or not happening. Show what standards of work should be. Communicate to everyone what performance measures are in place. Demonstrate all the elements required for safe and effective work. Provide real time feedback to everyone involved in the whole process. Cut down on meetings to discuss work issues.


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Techniques used in visual management

The techniques used to create a visually managed workplace fall into a number of

categories:

The workplace itself

Signs. Marked floor areas/hatching. Direction of process flow shown on floor or wall. Shadow boards to visibly store items frequently needed. Identified equipment & locationsincluding files, processing status, etc.

Visual information

Process documentation. Procedures - can be in the form of a one-point-lesson (all you need to know on

one page) or exemplars e.g. a form filled in showing the likely problem areas.

Skill & training boards to indicate competence development needs across theteam.

Visual production control

Visual process indicators (Jobs in progress, productivity, output, lead time,etc).

Maximum work-in-progress levels show to prevent over-production. Production status boards. Kanban visual signals. The machinery automatically stops when there is a problem and attracts

attention.

Visual performance measurement

Quality charts. Performance charts (dashboard metrics based on KPIs). Status of the organization.


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Visual safety management

Safety warnings. Precaution information.

The benefits of visual management

Apart from the overall outcomes of improving customer satisfaction, the

introduction of visual management tends to have a number of benefits, which include

greater employee involvement and motivation, as they feel more in control of what

they are doing; better communication; raised quality and productivity of work; faster

decision making processes; and less waste in processes.

2.4.1.1 ANDON SYSTEM

Andon - a Japanese term that refers to the warning lights on an assembly line

that light up when a defect occurs. When the lights go on, the assembly line is usually

stopped until the problem is diagnosed and corrected.

Nowadays, Andon at many manufacturing facilities is an electronic device: audio

and/or color-coded visual display. For example, suppose an Andon unit has three

color zones (red, green, and orange) and when the orange zone flashes with a

distinctive sound, it calls for an attention of and is signaling operator to replenish

certain material.

A tool of visual management, originating from the Japanese for "Lamp". Lights

placed on machines or on production lines to indicate operation status. Commonly

color-coded are:

- Green: normal operations.

- Yellow: changeover or planned maintenance.

- Red: abnormal, machine down.

Often combined with an audible signal such as music or an alarm.


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The typical Andon system

The typical Andon system is a manual system. Often consisting of a simpleseries of lights or flags to indicate that an area is experiencing a problem and

requires assistance.

Requires constant monitoring by support personnel and/or management. Requires personnel to perform further investigation to determine the nature of

the problem or assistance required.

Save time and resources Gives support personnel & management an at-a-glance view of in-work

status.

Reduces the need for technicians to interrupt their work, in order to acquireassistance.

Instant notifications. Configurable escalation schedules. Notifies only the appropriate personnel. Differentiate between emergent and scheduled needs.

Figure 2. 1 : Andon system


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Benefits of Andon

ProactiveProvides root cause analysis and decision data. ProductivityTechnicians can remain in the work area. CapabilityConsolidated support teams can support multiple areas. QualityProduction problems are identified and resolved quickly. MobilityVisually identify where resources are needed. ScheduleVisually identify when resources are needed. AllocationMetrics to support staffing & resource planning decisions. ValueStreamlined production processes and tracking.

Figure 2. 2: visual screen in the plant Figure 2. 3: screen is show status of plant

2.1.2CONTROLMANAGEMENT

2.1.2.1 PROGRAMMABLE LOGIC CONTROLLERS (PLC)

The automation of many different processes, such as controlling machines or

factory assembly lines, is done through the use of small computers called

programmable logic controllers (PLCs). This is actually a control device that consists

of a programmable microprocessor, and is programmed using a specialized computer

language. A modern programmable logic controller is usually programmed in any one

of several languages, ranging from ladder logic to Basic or C. Typically, the program

is written in a development environment on a computer, and then is downloaded onto


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the programmable logic controller directly through a cable connection. The program

is stored in the programmable logic controller in non-volatile memory.

Figure 2. 4: PLC box Figure 2. 5 : wires for PLC

Features

The main difference from other computers is that PLCs are armored for severe

conditions (such as dust, moisture, heat, cold) and have the facility for extensiveinput/output (I/O) arrangements. These connect the PLC to sensors and actuators.

PLCs read limit switches, analog process variables (such as temperature and

pressure), and the positions of complex positioning systems. Some use machine

vision. On the actuator side, PLCs operate electric motors, pneumatic or hydraulic

cylinders, magnetic relays, solenoids, or analog outputs. The input/output

arrangements may be built into a simple PLC, or the PLC may have external I/O

modules attached to a computer network that plugs into the PLC.

User interface

PLCs may need to interact with people for the purpose of configuration, alarm

reporting or everyday control.

AHuman-Machine Interface (HMI) is employed for this purpose. HMIs are

also referred to as MMIs (Man Machine Interface) and GUI (Graphical User

Interface).
http://en.wikipedia.org/wiki/File:PLC_Control_Panel.pnghttp://en.wikipedia.org/wiki/File:PLC_Control_Panel.pnghttp://en.wikipedia.org/wiki/Input/outputhttp://en.wikipedia.org/wiki/Sensorhttp://en.wikipedia.org/wiki/Actuatorhttp://en.wikipedia.org/wiki/Switchhttp://en.wikipedia.org/wiki/Machine_visionhttp://en.wikipedia.org/wiki/Machine_visionhttp://en.wikipedia.org/wiki/Electric_motorhttp://en.wikipedia.org/wiki/Pneumatichttp://en.wikipedia.org/wiki/Hydraulichttp://en.wikipedia.org/wiki/Relayhttp://en.wikipedia.org/wiki/Solenoidhttp://en.wikipedia.org/wiki/SCADA#Human_Machine_Interfacehttp://en.wikipedia.org/wiki/File:PLC_Control_Panel.pnghttp://en.wikipedia.org/wiki/SCADA#Human_Machine_Interfacehttp://en.wikipedia.org/wiki/Solenoidhttp://en.wikipedia.org/wiki/Relayhttp://en.wikipedia.org/wiki/Hydraulichttp://en.wikipedia.org/wiki/Pneumatichttp://en.wikipedia.org/wiki/Electric_motorhttp://en.wikipedia.org/wiki/Machine_visionhttp://en.wikipedia.org/wiki/Machine_visionhttp://en.wikipedia.org/wiki/Machine_visionhttp://en.wikipedia.org/wiki/Switchhttp://en.wikipedia.org/wiki/Actuatorhttp://en.wikipedia.org/wiki/Sensorhttp://en.wikipedia.org/wiki/Input/output


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A simple system may use buttons and lights to interact with the user. Text

displays are available as well as graphical touch screens. More complex systems use a

programming and monitoring software installed on a computer, with the PLC

connected via a communication interface.

2.4.2.2 SENSOR

A sensor is a device that measures a physical quantity and converts it into a

signal which can be read by an observer or by an instrument. For example, amercury-

in-glass thermometer converts the measured temperature into expansion and

contraction of a liquid which can be read on a calibrated glass tube. A thermocouple

converts temperature to an output voltage which can be read by a voltmeter. For

accuracy, all sensors need to becalibrated against knownstandards.

Figure 2. 6 : sensor laser
http://en.wikipedia.org/wiki/Mercury-in-glass_thermometerhttp://en.wikipedia.org/wiki/Mercury-in-glass_thermometerhttp://en.wikipedia.org/wiki/Thermocouplehttp://en.wikipedia.org/wiki/Voltmeterhttp://en.wikipedia.org/wiki/Calibrationhttp://en.wikipedia.org/wiki/Standardhttp://en.wikipedia.org/wiki/Standardhttp://en.wikipedia.org/wiki/Calibrationhttp://en.wikipedia.org/wiki/Voltmeterhttp://en.wikipedia.org/wiki/Thermocouplehttp://en.wikipedia.org/wiki/Mercury-in-glass_thermometerhttp://en.wikipedia.org/wiki/Mercury-in-glass_thermometer


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CHAPTER3:PROBLEMDESCRIPTION

There are no available tools exist in AVI to find bottleneck station and

evaluate its effects in assembly line. To solve this problem, our team designed a

constrain analysis tool based on the starve and block data of each station. The new

tool requires accurate and complete data collection from the plant.

After meeting the factory staff, the project team realized that new approach

cannot be implemented because of the lack of accurate data. The plant team was not

collecting the data in a correct method. They are collecting the data manually and this

mean that the data is not accurate. So, we convert the main objective of the project

from data analysis to collect data. In addition, we will put the data analysis in ourconsiderations.


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This is a sample of the data obtained from the plant (see the figure below)

Figure 3. 1: sample data from the plant.


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We analysis this data and the result has a lot of variations and doesnt match

actual situation (data is not accurate).

The data collection system requires modification for each station including:

1. PLC: it should have enough input and output exits to connect with computersand receive the information from sensors and Andon system.

2. Sensors: the absent of sensors has a negative effect in the station that lead theplant team to collecting the data manually

3. Monitors: there are no information display devices. If the station has aproblem ( over cycle start time end time help) , the flow of the

information is not reach to the manager and other stations.

3.1LAYOUT

Figure 3. 2 : show the layout of all stations.


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Figure 3. 3 : :Station 1 chassis assembly.

Station 1

Chassis assembly

Chassis are assembled with nails through a

special gun.

Figure 3. 4: Station 2 turn chassis.

Station 2

Turn Chassis

Chassis are assembled after turn through a

special gun

Figure 3. 5: Station 3 axles assembly.

Station 3

Axles assembly

Axles are ready to be installed on the

chassis.


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Figure 3. 6 : Station 4 cables assembly.

Station 4

Cables assembly

Wires are assembled.

Figure 3. 7: Station 5 cables assembly on chassis.

Station 5

Cables assembly on

chassis

Wires are installed on the chassis.

Figure 3. 8 : Station 6 radiator assembly.

Station 6

Radiator assembly

Radiator is assembled (fan, pipe and coolant

tank).


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Figure 3. 9: Station 7 engine assembly and gear box.

Station 7

Engine and gear boxassembly

Engine and gearbox are assembled

Figure 3. 10: station 8 engine with gear on chassis.

Station 8

Engine and gear box

assembly on chassis

Engine and gearbox are installed on the

chassis.

Figure 3. 11: station 9 radiator assembly on chassis.

Station 9

Radiator assembly on

chassis

Radiator is installed on the chassis.


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Figure 3. 12 : Station 10 tires assembly.

Station 10

Tires assembly

Tires are installed on the chassis by using a

fixture and special tool.

Figure 3. 13: Station 11 cab assembly.

Station 11

Cab assembly

Cab installed on the chassis.

Figure 3. 14 : final product

Final product

Trucks after MUL and road test

Then will be ready for delivery.

Table 3. 1 : Sequence of stations in the plant


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CHAPTER4:SOLUTIONMETHODOLOGY

After starting the deployment of our solutions in the project, we realized the

main problem we faced is wrong data collecting in the plant.

Here by our solution to such problem was focusing on developing collecting

method in order to develop the production respectively. In this regards we conducted

a lot of studies to reach the appropriate method of collecting the data.

Our solution was based on using automatic data collection system and

ANDON SYSTEM (visual management), and data analysis program to analyze the

data by using visual basic program (VBA).

4.1SOLUTIONCOMPONENT

1. Data collecting.2. Sensors.3. Push button.4. PLC and data analysis.5. Screens.

To achieve that, we have many steps in order to reach information that helps

to get the right decision.

4.1.1DATACOLLECTINGDESIGN

That why decided to use Andon system (visual management), in order to

supervise the production by monitor distributed all over the factory and connected

together by device called PLC and a computer where all the station are display on

these computer.


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4.1.2SENSORS

Sensor is to measure the starting time and ending time.

We used in each station four sensors works once the truck entered.

Figure 4. 1: sensor

The kind of the sensor sender and receiver(through beam).

Features

Designed for NEMA 6 / IP67 Narrow Beam for Small Object Detection Input 10-30 VDC, Dual Output (PNP & NPN) Separate Power and Signal LEDs Retro reflective and Diffuse PICO Style Quick Disconnect or 6 inch Pig Tail Available.


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In the figure 4.2and figure 4.3 below displays the design for the development of

sensors at station.

Figure 4. 2: top view for the station with sensors.

Figure 4. 3: side view for the station with sensors.


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4.1.3PUSHBUTTONANDSIGNALLIGHT

We used push button supported with a colored guidance signal to give us the

complete information about each station. So when the work is finished, pressing on

the green light button is required to send signal which mean that the work is done

.also there is a yellow button for help and red button to indicate that the work has not

been accomplished yet. All these are connected to the monitor, computer and PLC.

Figure 4. 4: Andon Light Visual Control System with Flashing Capability and Alarm.

Features

Any of the lights can be wired for flashing or solid, often the red is set toflashing while the other 2 are solid. Audible alert can be added to only ONE

light. If chosen light is set to flash, alarm (83db at one meter) will beep with

light on and off. If light is set to solid, alarm will be solid - Select via radio

buttons below.

Three toggle switches, one for turning on each of the three LED lights. 3 light design with remote switch box on 6 meter cord set. Allows for higher

light placement and better visibility.


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Standard power cord for connection to a 110 vac outlet. Unit mounted using a L-bracket - supplied with the unit. Adjustable tripod stand - optional - purchased separately. Units are approximately 24 in overall length.

4.1.4PLCANDDATAANALYSIS

Is a link between the computers, monitors, sensors and buttons, it is linked

all to other. So the plc receives data and then sends it to the computer and then the

computer distributes it to the screens.

Figure 4. 5: plc Siemens.

Features

cpu 226 compact cpu, expandable,16/24 kb ram for program, 10 kb ram for data, 24 v

dc supply voltage, 24 di/16 do.

4.1.5MONITORING

The monitor is divided into many parts and each has its own part that includes

all the required information and data. As well as starting time, ending time, guidance

signal and patch number.


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Three places had been chosen to fix the monitor on by which these monitor

can be clear and visible for all the factory staff, and that what is called ANDON

SYSTEM.

Figure 4. 6 : show the layout of all stations with monitor places.

Install screens on the figure 4.7 below

Figure 4. 7: install screen.


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4.2FINALDESIGN

The final design is for data collecting and visual management (monitoring

management).

From the figure 4.8 you can see four main components:

1- PLC (programmable logic control).2- Box button with different light or flashing.3- LCD (monitor).4- Computer.

Help button yellow flashing

Cycle complete green flashing

Over cycle 1:50 min red flashing

We will use sensors to measure the starting time, and cycle complete button to

measure the ending time.


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Figure 4. 8 : Final design of management monitoring system.

SN: means of station number.

ST: means of start time.

ET: means of end time.

BT: means of batch number.

TN: means of truck number.


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The previous components and devices that we suggest to add it in the plant. The cost

and quantities are shown in the following table:

Table 4. 1 : Total cost and quantities

NO. NAME QUANTITY COST(SR)

1Andon light visual control system with flashing

capability and alarm11 17532

2 LCD screen LG50'' full High-definition 4 20000

3PLC Siemens.

1 4813

4 Laser sensors (7700 series laser) ATC 22 11000

5 Installation cost all part and other cost 1 25000

Total cost 78,345


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4.3ANALYSISDATAUSINGVISUALBASICFORAPPLICATIONS(VBA)

We designed the program which will enable them to identify the bottleneck

and we need to test it by entering the data and analysis in the program.

Figure 4. 9 : picure show basic form in program.


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The Model in VBA

Figure 4. 10 : picture show model for program in VBA.


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The agreement with the plant to collect the required data which can test the

program .But after taking the initial data from the factory for analysis in the program

we found that they are collecting the data incorrectly and a manual. So we work on

the design control system (visual management) for data collection in the correct

method.

Test program.We decided to assuming the data close to the reality which show kinds of

problems that can occur in the plant, we have entered data in the program and analysis

as follows:

1 - A bottleneck in the first station:

In this case, the program is testing the constraint when the problem occurs in

the beginning of the line. This situation may happen when there is shortage of

material (truck) at the beginning.

Figure 4. 11: a bottleneck in the first station.


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2 - A bottleneck in the last station.

In this case, the same thing is happen but at the last of the line and this station

is the bottleneck because the cycle time of this station is high if we compare it with

line speed.

Figure 4. 12: A bottleneck in the last station.

3 - A bottleneck in two different stations.

In this case, there are two bottleneck station and this made the previous

stations blocking and the next stations are starving. So, in this situation the

manufacture lead time will increase.

Figure 4. 13: A bottleneck in two different stations.


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4 - A bottleneck at any station in the center.

In this case, the there is a bottleneck station in the middle of the line ( station

5 ) and this made the previous station block and the next station starve. So, in this

situation the manufacture lead time will increase but less than case 3.

Figure 4. 14 : A bottleneck at any station in the center.


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CHAPTER5:RESULTSANDDISCUSSION

Data collection.1- After meeting staff of the plant for data collection the plant approval

and satisfied

2- Data presentation.4 LCD distributed in the assembly line to present information

about production line thats good for plant.

Program (constraint analysis).1- Testing the program with the cases of single and double constraint

shows reasonable output.

2- We need more data, more real cases to get best result from program(constraint analysis).

3- VBA is enough for this project, we need different program when wehave more data.

We presented the idea to plant staff and explained to them and they approved,

but the process of implementation will be according to their potential and abilities.

For that they should study their budget and it is executed or not.


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CHAPTER6:CONCLUSIONSANDRECOMMENDATIONS

Conclusion

1) We confess about our mistake to made the plant team collecting the datamanually which is risk because its not accurate due to human mistakes

that appear to us when we saw them data ( see figure 3.1 ).

2) When start analysis, we conclude that if the data is not complete and notaccurate, then the result cant be trusted.

3) The automation of this plant increase the production even the automationhas a high cost but this will be covered by revenue of the increasing in

production.4) This project provided with good practical experiences because we had

many meetings with the plant engineer and understood their problem.

Recommendation

1) Data from the plantWe were disappointed for data collection , but were happy to

realize the real problem collection.

2) Design for data collection , more reliable data needed to get good resultsfrom the program.

3) PLC programming not included in our project.4) In the case of development of the production line try to use simulation

program.


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REFERENCE

1. Liker, Jeffrey (2004) "The Toyota Way" New York:McGraw Hill ISBN 0-07-139231-9v.20 n.1, p.32-40, January 1988.

2. http://www.zahid.com/en3. Hopp, W.J., Sp earman, M.L., (2008). Factory physics, third edition. McGraw

Hill, New York.

4. Goldratt, Eliyahu M.. Essays on the Theory of Constraints. [Great Barrington,MA]: North River Press.

5. http://www.volvo.com/trucks/global/en-gb/home.htm.6. www.Siemens.com/Saudi_Arabia.7. WEBSITE.ad-esse.com
http://en.wikipedia.org/wiki/Special:BookSources/0071392319http://en.wikipedia.org/wiki/Special:BookSources/0071392319http://www.zahid.com/enhttp://www.volvo.com/trucks/global/en-gb/home.htmhttp://www.volvo.com/trucks/global/en-gb/home.htmhttp://www.zahid.com/enhttp://en.wikipedia.org/wiki/Special:BookSources/0071392319http://en.wikipedia.org/wiki/Special:BookSources/0071392319


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APPENDICES

DATA


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continuous improvement application in vehicle assembly plant - project 2 report

Documents

plant management

truckassembly plant

abstractthe project

productiv ity improvement

system tps

correct data

production line

control management