712_12 CH 9 Organization of workstations +VPT

712_12 CH 9 Organization of workstations +VPT - 3/1/2012...

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3/1/2012 1 Chapter 9 Organisation of Workstations Konz & Johnson 2004 Equipment • Special purpose equipment – costs more, produces more Konz & Johnson 2004 Material • Special purpose material – costs more, produces more – E.g. tool steel – longer life, more expensive Konz & Johnson 2004 Labour • Specialists: – Have better quality – Have high productivity SOMETIMES SOMETIMES: – Work may be monotonous therefore an increased wage may be needed – Depends on the situations Konz & Johnson 2004 Job Organization • Depends on value Konz & Johnson 2004 Group Technology Form ‘families’ of similar products (capture localized economies of scale) Product design 1. Critical determinant of operations performance 2. Use DfA, DfM and DfM principles! Konz & Johnson 2004 >>
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3/1/2012 2 Group Technology • Re-use manufacturing resources • Cells: - grouping machines + process together for each product Higher output (specialized - Higher output (specialized) - Reduced handling cost - Decreased work in process (WiP) Konz & Johnson 2004 >> Group Technology • Problems: – Decreased utilization rates – Decreased flexibility – Set up and maintain costs for each family Layout • Layout: – Multiple machines/operators – Teamwork – Minimum involvement Konz & Johnson 2004 (Non) Progressive Assembly • Socio-technical vs. Tayloristic • How to divide the assembly task – e.g. VPT story Konz & Johnson 2004 (Non) Progressive Assembly >> Case Study: Volvo Powertrain Progressive and Non-Progressive Assembly Neumann, W. P., Winkel, J., Medbo, L., Mathiassen, S. E. and Magneberg, R. (2006) Production system design elements influencing productivity and ergonomics - A case study of paral el and serial flow strategies. International journal of operations & production management, v26(8): 904-923` Production Ergonomics - The Volvo D12 Project • Volvo Powertrain in Skövde • 12 liter diesel engines • Production System re- design – from kitted line & dock system – to a ’self-serve’ line system • Pre-Post Evaluation OLD ’DOCK’ Station NEW ’LINE’ System
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3/1/2012 3 Overview at Volvo Powertrain D12 DOCK system Components placed directly along the line ‘Dock’ system – parallel flow Line system – serial flow Losses in Serial Flow • Balance Losses – Uneven distribution of work between stations – Everyone knows about this System Losses • System Losses – Natural variability in performance causes blocking/starving in dependent stations up/downstream – Most people forget about system losses Parallel vs Serial Flow 0 50 Theoretical Observed Serial flow 1978&80 Parallel flow 1990’s Resources (% total t From Engström & Medbo 1995: Production system design - a brief summary of some design efforts Each assembler works alone in their cell work-station
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3/1/2012 4 D12 – Old ’Dock’ System (FINAL ASSEMBLY) Mellan-Del PICKING KITS BASE Assembly
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This note was uploaded on 03/07/2012 for the course IND IND712 taught by Professor Dr.patrickneumann during the Winter '12 term at Ryerson.

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712_12 CH 9 Organization of workstations +VPT - 3/1/2012...

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