IENG 343 Project4 (5% of total grade) April 11, 2006 Project is due on Tuesday, April 25, 2006. Late projects are deducted 5% per day. Project Purpose: To demonstrate the application of the various items learned in IMSE 343. To demonstrate that the student understands the material. Project Format: Include a table of contents with all pages numbered. You may use an appendix if you have any reference material. Type each question on the page you are putting the answer on. Use a new sheet for each of the Thirteen questions. Project 4 is to apply Just-in-Time, Lean Production and Agile Manufacturing Systems to your company and to analyze your company with regard to Operations Management. Also, itis an opportunity to explain what parts of the course impacted you. Project must be typed. Attach computer spreadsheets, graphs, etc. as appendixes or tables as needed but refer to page number so I can find the numbers quickly. Neatness, grammar, explanations, etc. are all important and points may be deducted. You must show a sample calculation where required to demonstrate that you have the right equation and that you can do the work if mathematical results are needed. Note: the purpose of your project paper is to convince me that you understand the material. Your explanations are NOT to be copied out ofthe book. Put the explanations in your own words and make them applicable to your own company that you setup. It is your responsibility to make assumptions and create any necessary data required to solve the problems. All numbers used in any equations must be the same as other calculated numbers or assumed numbers that you derived FOR YOUR COMPANY. > Please use your part number as a reference on everything when you refer to a part. > PARTNERSHIPS: Each partner is required to do each problem. Partners MAY NOT use the same part numbers or examples. You will need to work with your partners and make sure that there is no duplication. Note: There are 13 questions. Please put each question on a new page. 1, Lean Manufacturing - The Eight Wastes: (8 points) A. Discuss 2 of the eight wastes of Lean Manufacturing in your company where you might be able to reduce waste and what program or system would you implement to reduce the waste. Divide the wastes between partners — partners do not take same wastes 2. Pull System: (8 points) A. Explain using one of your manufactured component parts how you would change your factory to use a Pull System utilizing kanbans. B. Show an example where you calculate the number of kanbans required. Use the component demand from Project 3 (forecasted in Project 2 for 2006). Note: This is the only problem in Project 4, therefore you will need sample calculations.3. JIT Suppliers: (8 points) ‘A. Make up a vendor and explain what 2 of there concems would be in establishing a JIT Partnership. B. Explain how you would form a JIT Partnership for one of your purchased parts with the vendor above. 4. JIT Layout: (8 points) Write a paragraph or two on the following areas that would impact your company if you provided JIT layout systems throughout your company: A. Increased flexibility of your company B. The impact on your employees 5¢ JIT Inventory: (8 points) Write a paragraph or two on the following areas that would impact your company with regard to your inventory in your company if you provided JIT systems through out your company: A. Reduction in inventory (how) B. Reduction in lot sizes — how would this affect your inventory. C. Reduction in setup costs (how would you reduce the setup). Pick a manufactured one of your component parts and give (demonstrate) an example. Show the reduction in setup costs that you get. 6. Lean Manufacturing — Visual Management: (4 points) Explain how you would implement a “Visual Management” System somewhere in your company. Note: you cannot use the Pull system or Kanban in your example. Use an illustration within your company of implementing the techniques of using “visual management” in the operation of your company. 7. Lean Manufacturing - 5S Workplace Principle: (4 points) Explain how you would implement the “SS Workplace Principle in your company. 8./ Lean Manufacturing ~ Continuous Improvement: (4 points) Explain how you would implement the philosophy of continuous improvement by utilizing Quality Methods in your company. You may pick one “quality method to demonstrate this. 9. Lean Manufacturing -Poka Yoke: (4 points) Explain how you would utilize or implement “Poka Yoke” in the manufacture of one of your component parts. 10. Agile Manufacturing: (8 points) Explain what the four core concepts are for Agile Manufacturing, 11. Agile Manufacturing vs. Lean Manufacturing: (6 points) Explain the difference between Agile Manufacturing and Lean Manufacturing. Also, explain how you would be able to use Agile Manufacturing in your company.12, Company Performance Summary: (15 points) A. Discuss your calculated inventory carrying cost rate and tell me if you think itis accurately represented for your company. Discuss your inventory stocking costs. B. Discuss your inventory measurements: inventory tums and ROI. Explain good/bad based on your company and strategies. C. Discuss the viability of your company. Discuss break even, opportunity to make a profit. Is ita feasible company based on your numbers? If you had the money or were to invest in a company similar to the company you set up in this project, would you? Explain D. Discuss whether you should be either managing demand or managing capacity (or both). Why ‘you should or why you should not be doing this? How would you manage either the demand or ‘the supply. Explain based on your three products and your associated business structure and costs. E, Discuss whether the costs you set up for Material, Labor, Overhead and Selling Price was good or bad. Explain what you would have done differently for Project 1, 2, and 3 based on what you eared about your company in this course and doing the projects. 13. Course Conclusion: (15 points) Write and explain what made the largest impression on you about the material you learned about Operations Management as it relates to each of the following areas: A. Forecasting B. Setting strategies for competitiveness and production, as well as, evaluating those strategies (S.W.O.T,, etc.) and doing benchmarking studies. C. The product life curve and how the position on the curve for products affects the strategies. D, Inventory management in regards to earrying costs. E. Supply-chain management in regards to purchasing Kenton Colvin/IENG 343 Project 4/Spring 2006