1. IE 376 – Project Assignment Ford Motor Company Plastics Division JIT implementation

2. The Sandusky, Ohio, plastics plant Produces head, side and tail lamps, temperature switches and door latches for air cleaners Tail lamps –Lens, clips, studs, butyl, gaskets (purchased) –Body (produced)

3. Tail lamp production Molding Painting Assembly Packing Shipment

4. Molding department 19 700 ton machines ($900000) 2 1000 ton machines 8 different types of molds ($100000) The types of molds required for each model, the types of the cavities and the cycle time in seconds are provided. Exhibit 4: Escort540 (2 available) 254 Thunderbird642 (left side only) 169

5. Molding department (contd) The press assignment for each mold type is provided. (for a day) Exhibit 5: m/c no.m/c typemolds assigned 30700569479639 The setup times: –45 min, 1 hour 45 min, 4 hours Tail lamp production is 10% of the total workload of 21 machines (page 7)

6. Molding department (contd) The production plan for each mold type is provided. (for a week) Exhibit 6: moldweekly schedule (units) 5392874 Mold cycle time for mold type 539 is 54/2=27 seconds/unit

7. Painting Two lines 700-900 units per hour per line can be produced The setup time is 3-5 minutes Only one shift 8 workers

8. Assembly Two flexible assembly systems Two shifts Setup time 20-30 minutes Standard production rates for each model are provided. Exhibit 8: Part namenet 8 hr standardcycles/hr Escort Rear (R&L)2780 450

9. Shipping Rails and trucks are used for shipments. One weeks daily shipping schedule for each model is provided in exhibit 9. The assembly plant locations are provided in exhibit 3. ModelMon.Tues.Wed.Thurs. Fri. Lynx2419041190411 Lynx is produced in Canada and New Jersey

10. Planning 4-week plans (20 production days) Weekly tail lamp production requirement schedule by month for each model is provided in exhibit 2. AIM: To operate under just-in-time philosophy.

11. What do we want from you? Evaluate the performance of the existing system under JIT philosophy. –What are the problems at each stage (from purchasing to shipping)? –How can you solve the problems mentioned above?

12. What do we want from you? (contd) We provide some questions, which will help you to analyze the system. Find some other key questions Answer the questions Support your ideas by using the information provided in the text. –Show calculations when necessary –You can make assumptions, but state them in your report Write an engineering report.

13. Example The problem: The capacity is not enough to satisfy the demand in department X. –Show that demand > capacity –How did you calculate the capacity? Solution method: Buy a new machine –Is the investment cost justified?

14. Office Hours Esra Koca –Office: EA330 –Office Hours: April 15, 12:30 - 14:30 April 29, 12:30 - 14:30 Özge Şafak –Office: EA327 –Office Hours : April 17, 13:00 - 15:00 April 24, 13:00 - 15:00