Lean Manufacturing and Services | My Assignment Tutor

UNIVERSITY OF HERTFORDSHIRESchool of Physics, Engineering and Computer SciencePage 1 of 7 COURSEWORK ASSIGNMENTModule Title: Lean Manufacturing and ServicesModule Code: 7ENT1128Assignment Title: Assignment 3 –Tesla Model 3 Rear Knuckle Assembly FacilityIndividual AssignmentTutors: Thomas Baker & Shane McCalisterInternal Moderator: Dr. Peiqing Cao Student ID Number ONLY:Year Code: Marks Awarded %:Marks Awarded after Lateness Penalty applied %:Penalties for Late Submissions• Late submission of any item of coursework for each day or part thereof (or for hard copy submissiononly, working day or part thereof) for up to five days after the published deadline, coursework relatingto modules at Levels 0, 4, 5, 6 submitted late (including deferred coursework, but with the exceptionof referred coursework), will have the numeric grade reduced by 10 grade points until or unless thenumeric grade reaches or is 40. Where the numeric grade awarded for the assessment is less than40, no lateness penalty will be applied.• Late submission of referred coursework will automatically be awarded a grade of zero (0).• Coursework (including deferred coursework) submitted later than five days (five working days in thecase of hard copy submission) after the published deadline will be awarded a grade of zero (0).• Where genuine serious adverse circumstances apply, you may apply for an extension to the hand-indate, provided the extension is requested a reasonable period in advance of the deadline.Please refer to your student handbook for details about the grading schemes used by the School whenassessing your work. Guidance on assessment will also be given in the Module Guide.Guidance on avoiding academic assessment offences such as plagiarism and collusion is given at thisURL: http://www.studynet.herts.ac.uk/ptl/common/LIS.nsf/lis/citing_menu UNIVERSITY OF HERTFORDSHIRESchool of Physics, Engineering and Computer SciencePage 2 of 7 ASSIGNMENT BRIEFStudents, you should delete this section before submitting your work.This Assignment assesses the following module Learning Outcomes:LO3 -Compare and contrast models and techniques.LO4 -Justify and evaluate manufacturing processes applying Lean Manufacturing Techniques andTOC.Assignment Brief:You are to design the assembly line layout and the supporting part warehouse layout for assembling TeslaModel 3 rear brake knuckles as detailed in the assignment brief which forms part of this document.Submission Requirements:To be submitted individually, electronically on studynet as:Part 1 – 1x PDF documentPart 2 – 1x PowerPoint (.ppt or .pptx file) OR a pdf document .This assignment is worth 28 % of the overall in- course assessment for this module.Marks Awarded:A mark out of 100 which can be broken down as follows:Part 1 – Layout drawing10 Marks – Clarity, presentation and accuracy of your layout drawing.30 Marks – Simplicity, Information, Adequacy and Efficiency of Warehouse and line layouts .30 Marks – Simplicity, Information, Adequacy and Efficiency of Materials handling Routes.Part 2 – Logic and Theory Behind the design & Outcome.30 Marks – Explanation and outcome of your design.A note to the Students:1. For undergraduate modules, a score above 40% represent a pass performance at honours level.2. For postgraduate modules, a score of 50% or above represents a pass mark.3. Modules may have several components of assessment and may require a pass in all elements.For further details, please consult the relevant Module Guide or ask the Module Leader.Typical (hours) required by the student(s) to complete the assignment: 30 hoursDate Work handed out:Week 34Date Work to be handed in:Week 42:Target Date for the return ofthe marked assignment:4 weeksType of Feedback to be given for this assignment:Written feedback, plus opportunity to discuss the feedback at bookable sessions. UNIVERSITY OF HERTFORDSHIRESchool of Physics, Engineering and Computer SciencePage 3 of 7Assignment BriefingSCENARIO: You need to design the assembly line and warehouse layout for the Tesla Model 3 rearbrake hub, knuckle and suspension. Assume that the facility is separate from the rest of the Teslafactory, and that the parts will be delivered to the facility (see appendix 1), and after being assembled,be shipped to the Tesla factory.Part of your consideration is that you will need to hire a building to do this, and you need to design alayout before selecting an appropriate building. You are considering a number of square buildings ofdifferent sizes available to you and you wish to hire the smallest building possible to minimize on rent,heating, lighting and other costs. Both the assembly line and the warehouse layout need to be in thesame building, separated by a STRAIGHT wall. Moreover, you also need to consider the ongoingcosts of running your forklift truck(s) inside the plant.Thus, for this assignment you are to design the assembly line layout and adjoining warehouse layout,as well as each work station’s layout (according to the demand stated below) for a Tesla model 3’srear axle assembly for the parts shown in appendix 1, based on a demand for parts for 200 vehiclesa day.For this process, assume that:Stations 1, 2 & 3A & 3B (represented below) assemble their sub-assemblies in parallel at the samerate, which are combined at station 4. Completed assembles are then transported to the warehouse. FORKLIFT TRANSPORTSTATIONOPERATORSTATIONFORKLIFTTRANSPORT Your aim is to design a layout can accommodate your process that:♦ Has the smallest overall size♦ Minimises operator walking♦ Minimises distance travelled by forklift trucks which carry the palletsYour submission should consist of the following:Part 1 – Layout Drawing – PDF DocumentPart 2 – Part B – Logic and Theory Behind the design 1x PowerPoint (.ppt or .pptx file) OR a pdfdocument . PARTS FROM WAREHOUSEPARTS FROM WAREHOUSEPARTS FROM WAREHOUSE 12Completedassemblies towarehouse SUBASSY 43A PARTS FROM WAREHOUSE 3BUNIVERSITY OF HERTFORDSHIRESchool of Physics, Engineering and Computer SciencePage 4 of 7Part 1 – Layout Drawing – PDF DocumentUsing either:♦ a CAD package of your choiceOR♦ the spreadsheet template provided where each square cell represents 1mx1m,Generate a dimensionally accurate layout of the building, showing the following:A) The layout of the assembly line, showing the following:♦ Assembly station locations,♦ Assembly station part storage, Assume that “boxes” are stored on the workbench.♦ The forklift truck movement needed for material flow.♦ WIP (or Kanban) areas between stations as appropriate:♦ If stations 1, 2 or 3A or 3B are alongside station 4, provide a WIP area for ashelf for each subassembly of 1x1m.♦ If stations 1, 2 or 3 are more than a few steps away, assume that you havetrolleys (1x1m) which workers manually push to the next station. Assume you’llneed 3 trolleys per subassembly for this purpose.♦ Assume each trolley / shelf has a capacity of 4 subassemblies.It is not necessary to show the detailed layout of the actual assembly stations – simplyindicate its footprint. You should arrange your part storage around these areas allowing forconvenient access (i.e. minimum walking) to the parts and the workstations by the assemblyworkers. Assume that each assemblystation has a footprint of2mx3m (includes workbenchand standing area): B) The layout of the warehouse with appropriately sized areas for each part, assuming:♦ Maximum of one delivery of parts each week (Mon – Friday) – assume that each deliveryfor a part might be on ANY day of the week and might vary from one week to the next.Also assume different parts might be delivered on different days.♦ ONE shipment of completed assembles leaves the facility each day at the end of the shift.♦ Left and right completed assemblies can be packed into identical stillagesinterchangeably.See Appendices for part dimensions, capacities etc.UNIVERSITY OF HERTFORDSHIRESchool of Physics, Engineering and Computer SciencePage 5 of 7C) You will need to develop a strategy for transporting PARTS ON PALLETS (ONLY). On yourdrawing, show the precise route of travel of your transporter for each part / assembly / empty palletbeing transported.On your layout, show each route of travel in a different colour as appropriate and label the route oftravel.Assume that for each pallet of PARTS the forklift needs to:Weekly:♦ move the pallet from the delivery truck bay to its location in the warehouseAs required:♦ collect the part from the warehouse♦ deliver to the assembly line♦ dispose of empty pallet in the warehouse.Part 2 – Logic and Theory Behind the design and outcome.This should consist of 2 parts:A. In this section you have the opportunity to explain to the markers the logic and theory you’veused in creating your design (for example how you have endeavoured to minimise Ohno’swastes).B. Calculate the monthly distance travelled by the forklift truck (s) which transport parts onpallets. You can ignore transportation on small parts in boxes. Show your assumptions andcalculations. Suggestion: use a spreadsheet.C. State the overall minimum size of the layout you have designed.You have a choice on how to submit this:♦ As a narrated PowerPoint presentation – maximum 5 minutesOR♦ As a PDF file – Maximum ONE A4 page explanation (Arial font size 12) and Maximum TWOA4 pages calculations / spreadsheet printout. Total Three pages Max.This will be marked alongside your drawing from Part 1, so you do not need to redraw parts of yourdrawing. Simply refer to clearly labelled points on your drawing as needed.UNIVERSITY OF HERTFORDSHIRESchool of Physics, Engineering and Computer SciencePage 6 of 7General Notes, Requirements and Constraints:1. In the warehouse, show each location for parts as an appropriately dimensioned andlabelled area.2. In the warehouse, show the location for completed assemblies in appropriately sized anddimensioned area.3. Provide an area 20% larger than one day’s production for completed assemblies in thewarehouse where they will await shipping4. Provide transportation for the completed assemblies from the final station to thewarehouse.5. Assume that loaded pallets can NOT be stacked. Assume that boxes can be stacked /put on shelves 2 boxes high.6. Aisles should be a minimum of 3m wide to allow for forklift access.7. Assume that (for security reasons), you wish to keep the warehouse area separate butadjoining to assembly area, with a 4m wide doorway in a STRAIGHT wall that separatesthem. The position of the doorway can be anywhere along this wall.8. Assume that the warehouse area has a loading / unloading area adjoining the streetwhere delivery vans / small lorries can reverse into, of 5m wide x12m long9. Assume that the footprint of each pallet is 1m x 1m10. Assume that empty pallets can be stacked up to 10 pallets high – provide an area forempty pallets in the warehouse, assuming that they are cleared after the end of eachshift. This is done by an external contractor who will (using their own equipment) movethe pallets from this storage area in the warehouse to the loading / offloading bay.11. Assume that boxes / pallets are unpacked by the operator directly at the assemblystation.12. Clearly show the outside boundary of your area needed as a thick dashed line. It is notnecessary to draw details of the actual potential building13. It is not necessary to make provision for rest areas / toilets office space. Assume thatthese are catered for on a raised area which you do not have to draw.14. Assume that completed assemblies are placed on stillages. Assume that TWELVEcompleted assembles can be placed on each stillage at station 4. Assume that thestillages for this (similar to the one below) – dimensions 1mx2m are recycled on anongoing basis between your assembly operation and Tesla. At the end of each shift, allthe full stillages are shipped to Tesla, and replaced with empty ones ready for the nextday.https://www.stillagesandcages.co.uk/non-standard-designs/.UNIVERSITY OF HERTFORDSHIRESchool of Physics, Engineering and Computer SciencePage 7 of 715. Assume that there are no quality problems from suppliers or in the operations16. You do not have top specify emergency exits or fire escapes

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