Coursework (Timesheet Analysis)

Module Code: GEEN1042

Module Title: Process Improvement Techniques

Programme: MSc Engineering Management

Student Name: Fahad Mohammed A Alnamlah

Student ID: 001086420
Module Leader: Baker Grahame

Submission Date: 7th December 2020

Table of content:

1. Introduction

2. Adopting new ways to enhance output

i. Lean management process

ii. 5s system
iii. Operational effectiveness
iv. Safety and standardization
v. Making the simplest decisions
vi. Choosing the simplest methods
vii. Availing every finite opportunities.
viii. Vast knowledge
ix. Quality of performance
x. Creation of a clean, orderly environment
xi. Improvising the itemization process
xii. Modern simulation software tools
xiii. Improve employee training
xiv. Use factory automation
xv. Minimize physical prototyping where possible
xvi. Reduce the parts rejection rate
xvii. Eliminate throughput bottleneck
3. Output analysis
4. Gantt chart Analysis
5. Conclusion
1. INTRODUCTION:
In today’s competitive world, there are numerous companies who actually develop their
own area with few resources. And at the top , they have more beneficial from the
manufacturing of the merchandise department.
2. ADOPTING NEW WAYS TO ENHANCE OUTPUT:
Means there are numerous businesses, which opted few resources to urge more benefits
from it. to urge more benefits, we'd like to enhance the output of our machines which are
explained below:

i. Lean management process

one of the easiest ways to extend the effectiveness and efficiency of the
merchandise is to adopt the lean management technique. lean manufacturing
technique attributes characterized by both the technology push and market pull
have forced the organizations to understand the increment in performance, which
continuously improves the products and its processes.
Different industries are implementing the lean method for production of superior
and better product in limited period of time with fewer efforts Manufacturers of
any production based factories or companies have always encountered challenges
like rising customer's expectations, fluctuating demands, competition, product
price, base level cost of the merchandise , product quality and merchandise
quantity within the market. it's an idea , which allows the development of the
assembly process and it presumes the elimination of all waste occurring on the
assembly , which results in a discount within the transit time of the fabric by the
method today’s world of producing , assembly work is routinely characterized by
the short production cycle and constantly retreating batch sizes, while the
variability of the merchandise types and models continues to extend .
Lean cares with eliminating all kinds of process wastages and improves the
efficiency of your time taken for the making in product.
The waste is usually hard to ascertain in ongoing process, but it are often
classified by overproduction, time available, transportation, over processing,
 inventory, movement and defective products. a corporation striving to be lean
will want to possess only the specified inventory when needed, improve quality to
zero defects, reduce time interval through setup time reduction, reduce queue
lengths and sizes, incrementally revise operations and to attain improvement at
the minimum costs and resources

ii. 5S SYSTEM
5S system is such business and industrial method, which has focus on the
assembly ratio and improvement of its process. It contributes quite 50% of the
economic production in value additional term and one-third export revenue. This
system is employed by the Japanese organizations, which incorporates 5 different
S: i-e sort, set in order, shine, standardize and sustain. These technique aids in
developing workplace with efficiency and reduces the wastage and improve
quality and production through monitoring of an organization environment. The
manufacturing service, for profit, not for profit, education and health businesses
are often improve through the assistance of this system. It’s dramatic impact on
safety and environmental issues, loss of resources and lots of others. 5S will
foster teamwork; discipline and can boost the responsibility and concern for
company. 5S will generate clean and constructive work environments and protect
a delivery system towards a world -class.

On-going commitment from management and involvement are the cornerstone of

all citizens for the successful implementation of 5S practices.
 Figure 1 - 5S Arms
iii. SAFETY AND STANDARDIZATION
Safety and standardization are vital parameters to extend the assembly of the
merchandise in any big or small industry.

iv. OPERATIONAL EFFECTIVENESS

With the contraction of various barriers and therefore a pressure of competition during
this tough global market, overall the operating effectiveness has developed a necessity
for the organizations.

v. MAKE THE SIMPLEST DECISIONS

Managers need to make the simplest decisions. Decision making may be a central
responsibility of managers and leaders. It requires defining the difficulty or the matter
and identifying the factors associated with it. Doing so helps create a transparent
understanding of what must be decided and may influence the selection between
alternatives.

vi. CHOOSE THE SIMPLEST METHODS

Choose the simplest methods to realize their objectives. This would improve the output
and efficiency of the product.

vii. AVAILING EVERY FINITE OPPORTUNITIES.

A worker should not lose very finite opportunities. These opportunities provide better
way to increase output therefore these chances should not be wasted.

viii. VAST KNOWLEDGE

Lack of data is one among the foremost important problems of managers about
familiarity with an appropriate method to successfully enhance the functioning of
organization. Thus knowledge about particular process and management is very
important to enhance the production.

ix. QUALITY OF PERFORMANCE

Additionally, the standard of performance is also vital to be evaluated and recognized.
Such an evaluation can help managers to spot the development of performance.

x. CREATION OF A CLEAN, ORDERLY ENVIRONMENT

A Person should develop a clean, suitable, fresh and orderly environment- an
environment which has an area for everything and everything is in its place.

xi. IMPROVIZING THE ITEMIZATION PROCESS

The aim is thus to create an approach to enhance the itemization process which might
increase the standard of knowledge in terms of component knowledge accuracy, reduce
its delivery time, and would within the end increase competitiveness towards competitors

xii. MODERN SIMULATION SOFTWARE TOOLS

What modern simulation software tools are able to do is to afford solutions for improving
the productivity of the present manufacturer schemes by ascertaining the performance of
the system. Thus, possible improvements inside the assembly line were recognized and
applied in an improved scenario model.

xiii. IMPROVE EMPLOYEE TRAINING

The frontline workers manning the assembly line have an enormous impact on
manufacturing cycle efficiency and merchandise quality.
When employees lack the required training, they'll struggle to seek out improvements
that they will make. Worse yet, undertrained employees may accidentally create delays
because they don’t understand everything of the assembly process and the way a tweak
that saves them a moment creates 5 minutes of additional work for somebody else.
Focusing on employee training in order that they have the talents to form positive, well-
informed changes to the assembly process is vital to maximizing throughput.

xiv. USE FACTORY AUTOMATION

Figure 2 - Automation

By utilizing productive automation, manufacturers have increased the throughput in

greater amount and improve the standard of life for his or her workers. The workers or
manufacturers who would once require backbreaking heavy labor for bending thick steel
wire can become specialist in programming, planning, and other cerebral works but the
machines do the damaging work.
Unlike a person's worker, manufacturing machines don’t get tired from workout. Each
and each operation is administered with an equivalent machine-like precision for hours
on end. This helps make sure that every part produced will meet an equivalent production
tolerances.

xv. MINIMIZE PHYSICAL PROTOTYPING WHERE POSSIBLE

Development of a physical prototype of a neighborhood or result may be a slow, time-
taking and expensive process. If the prototype does not meet the necessities of a
customer then all of the tooling and time spent thereon prototype will attend waste. A
Steel industry responded to this issue by utilizing a physics simulation software that
can run practical tests of productivity designing before commitment to tooling for the
physical product. These virtual tests are often administered in just minutes, and any
issues that may cause the merchandise to fail are noted within the simulator for
engineers to repair.
This helps to make sure that the assembly run is that the only run.
When a physical prototype is important, one can produce many items that might
normally need special tooling by employing a 3D printer instead. While less efficient
than traditional production for giant product runs, the 3D printer is right for a limited,
one-time production because it eliminates the necessity for tooling.

xvi. REDUCE THE PARTS REJECTION RATE

Figure 3 – Defected parts

Raw manufacturing capacity is vital. However, it’s possible to possess a high output,
but still fail to satisfy throughput goals due to parts rejections.
If a manufacturer can produce 1,000 parts per hour, but features a 10% rejection rate,
 they’ll waste 100 parts every hour, or 800 parts a shift. Were this manufacturer to chop
their rejection rate by half, throughput would increase by 400 parts per shift. this is
able to make it far easier to satisfy quotas, and reduce money wasted on
remanufacturing or reprocessing parts.
Search the elements of your production process which will destruct your components
or cause it to fail in satisfying the production tolerances. Through identification and
remediating these issues, you'll improve production throughput

xvii. ELIMINATE THROUGHPUT BOTTLENECK

One of the most effective way to enhance throughput in manufacturing is to carefully
analyses your production process for bottlenecks. Once identified, you'll work to
eliminate the bottleneck in order that it not delays production.
Some solutions could also be to feature extra stations to an extended process so more
parts are often processed directly, or to seek out ways to form the method more
efficient, or possibly even eliminate the method entirely and replace it with a special
one. The answer depends on factors like spare floor space, expense of kit involved, and
therefore the nature/necessity of the method.

3. OUTPUT ANALYSIS:
The table and graphical representation shown below demonstrates the output of
products like brass and tin in radiators and heat exchanger industries.

day %age %age output output after using reducing eliminating

output output after after using factory parts throughput
lean adopting simulation automation rejection bottlenecks
management 5S software rate
Monday 45 78 76 99 78 87 78
Tuesday 39 89 97 93 74 72 89
Wednesda 48 79 94 92 89 67 69
y
Thursday 29 90 91 98 88 88 83
Friday 57 83 89 97 81 87 78

4. GANTT CHART ANALYSIS:

Chart 1 – Analysis of outputs

5. CONCLUSION:

After the implementation of Lean management and Upgrading the systems to New
software’s and Bringing automation increased the output to a very large range and hence
a lot in improving the output.
References:
1. John Williams , Cheryl Brown, Anita Springer, Overcoming benchmarking
reluctance: A literature review, 2013
2. Sara Abdalrazig Sati, Abdelmutalab Adam, Evaluating the effectiveness of 5S
implementation in the industrial sector, 2019
3. Marlin steel,  Effective Ways to Improve Manufacturing Throughput, 2016