1

OWNER:

Chris Keating

PROJECT LEADER: Tracy Hutton

TEAM MEMBERS: Dr. Shahrukh Irani

Sachin Varkey Vasudev Nalapat

Ramkumar Harikrishnakumar

Design of Overall Factory Layout

2

Acknowledgement

The project team wishes to sincerely thank Dr. Smart Khaewsukkho, Ph.D., for granting us unlimited use of his

Flow Assessment Tool (FAT) app for this project. If you have questions about the app, please directly contact Dr.

Khaewsukkho by email (Khaewsukkho.1@gmail.com) or phone (614-598-0642).

3

Objective Strategies Measures Product Flow: Reduce steps in current process by 20%. New/Rebuild Lead Time Reduction: Reduce Lead times by 10%. Customer Delivery Performance: 95% OTD to promise

Design short-term & long –term factory layouts subject to the current constraints and incorporation of new CNC machines Investigate the feasibility of a future factory layout with separate focused factories for New & Rebuild screws Utilize PFAST software and FAT app to visualize and analyze the production flows in the different layouts Use quantitative metrics such as Lead Time, Labor Cost and Material Handling Distance to evaluate proposed layouts

Reduce Lead Time and Production Cost by designing an overall factory layout to improve flow and shop floor control

Goals

Material handling distance

that Water Striders have to

push carts that weigh 100-

1300 lbs. throughout the

year will be reduced by 100

miles

Lead time for a set of New

screws will be reduced by

≈11 days

Annual Labor Cost of

material handling will be

reduced by ≈ $56,925

Project - OGSM

4

Current Factory Layout

BOXING & ASSEMBLY

FINISH INSPECTION

MAGNAFLUX

WEINGARTNER

COBURG 1COBURG 2

MAZAK

PBR LATHE

MORI NT6600

NEW SMTW (G5)NORTON GRINDER (G7)

TANK NEUTRALIZE

TM1

TM2

TM3

TM4

MASK

BLAST

STELLITE PTA1

STELLITE PTA2

WIR

E WELD

SPRAYCORE DRILL

W TOSS LATHE

N TO

SS LATH

E

SAW

PO

LOSH

BO

OTH

S

PRESS

MAINTENANCE

HOB MACHINE

SHA

RP

M

ILL

SHA

RP

LA

TH

E

WE

BB

LA

TH

ET

AR

NO

W

LAT

HE

BRIDGEPORT

DA

EWO

O

E TOSS LA

THE

PA

RA

LLELSIM

SAN

D

BLA

ST

CONICAL SIM

VDF LATHE

OV

EN

EITEL PRESS

WIRE WELD

PRE-INSPECTION

BARREL INSPECTION

Machine Shop

CNC Department

Thread Mills

Grinders

Welding

Polish

Straightener Press

Simulation

5

Production Flow in the Current Factory Layout

Distance travelled by a new set of screws

is ≈ 1 mile in a 63,000 sq.ft. facility.

6

Layout 1: Proposed Moves

Changes made in current factory layout to realize this new layout:

Raw material enters main facility through the Maintenance door

Move Pre-inspection to warehouse

Move Boxing to current location of Pre-inspection

Move Final Inspection & Barrel Inspection to current location of Boxing

Move Daewoo, Bridgeport & Webb lathes next to Boxing department

Move Yellow Press (P1) across from the Weingartner to create a cell that includes the SIM

station for parallel screws

Move Sharp Mill, Tarnow Lathe & Sharp Lathe to current location of Saw

Move East TOS Lathe to current location of the Sharp mill

Move West TOS Lathe to current location of Daewoo

Move Saw to current location of East TOS Lathe

Move Eitel Press (P2) to current location of West TOS Lathe to create a cell that includes

the Coburgs, Hob and SIM station for conical screws

7

Layout 1: Constraints/Assumptions

Machines/departments in the current factory layout that were not moved:

Weingartner

Due to its heavy foundation

Core Drill

Due to its age, the machine has experienced considerable wear and tear; any

attempt to move it could damage it irreparably

Mori Seki

Due to its heavy foundation

Welding Department

Difficult to run gas lines

‘Dirty’ Departments – Spray, Blast & Mask

Requires a closed room

Polish Department

Current location is good

8

BOXING & ASSEMBLY

FINISH INSPECTION

MAGNAFLUX

WEINGARTNER

COBURG 1COBURG 2

MAZAK

MORI NT6600

NEW SMTW (G5)NORTON GRINDER (G7)

TANK NEUTRALIZE

TM1

TM2

TM3

TM4

MASK

BLAST

STELLITE PTA1

STELLITE PTA2

WIR

E WELD

SPRAYCORE DRILL

W TOSS LATHE

N TO

SS LATH

E

SAW

PO

LOSH

BO

OTH

S

PRESS

MAINTENANCE

HOB MACHINE

SHA

RP

M

ILL

SHA

RP

LA

TH

E

WE

BB

LA

TH

ET

AR

NO

W

LAT

HE

BRIDGEPORT

DA

EWO

O

E TOSS LA

THE

PA

RA

LLELSIM

SAN

D

BLA

ST

CONICAL SIM

VDF LATHE

OV

EN

EITEL PRESS

WIRE WELD

PRE-INSPECTION

BARREL INSPECTION

WAREHOUSE

PBR LATHE

1

2

3

4

5

6

7

8

9

10

Layout 1: Proposed Machine Moves

Re-located Machines/ Departments

Fixed machines

* Arrows indicate the proposed location changes for the machines

9

BOXING & ASSEMBLY

FINISH INSPECTION

MAGNAFLUX

WEINGARTNER

COBURG 1COBURG 2

MAZAK

PBR LATHE

MORI NT6600

NEW SMTW (G5)NORTON GRINDER (G7)

TANK NEUTRALIZE

TM1

TM2

TM3

TM4

MASK

BLAST

STELLITE PTA1

STELLITE PTA2

WIR

E WELD

SPRAYCORE DRILL TOSS LATHE

N TO

SS LATH

E

SAW

PO

LOSH

BO

OTH

S

PRESS

MAINTENANCE

HOB MACHINE

SHARP MILL

SHARP LATHE

WE

BB

LA

TH

E

TARNOW LATHE

BRIDGEPORT

DAEWOO

TOSS LATHE

PA

RA

LLELSIM

SAN

D

BLA

ST

CONICAL SIM

VDF LATHE

OV

EN

EITEL PRESS

WIRE WELD

BARREL INSPECTION

Layout 1

Bar stock enters through here

* Diagram is not to scale, kindly refer AutoCAD version

Re-located Machines/ Departments

Fixed machines

Cell 1

10

Layout 1: Implement a Cell

Pre-inspection, Boxing, Final Inspection & Barrel Inspection moved Yellow Straightener moved and re-located across from the Weingartner in a cell

Form a cell comprised of Weingartner, Yellow Straightener and SIM station

With the Yellow Straightener in its current location, large screws have

to move back-and-forth between the Straightener

and the Weingartner at least three times

11

Layout 1: Split a Department into Process Cells

Additional reduction in Material Handling Distance would have been achieved if the App had been able to choose between the Presses P1 & P2 in different routings.

12

Layout 1: Benefits

Employee Safety

Approximate material handling distance travelled by a new screw set = 1 mile = 5280 ft.

Material handling distance reduction obtained from Layout 1 = 20% = 1056 ft.

Average number of sets of screws done per month:

New screws: 24 sets Rebuild screws: 12 sets Repair screws: 12 sets

Coating screws: 12 sets

Water Striders are solely responsible for pushing carts that weigh between 300 – 1600 lbs.

Assuming that Rebuild, Repair & Coating screws travel half the material handling distance compared to New screws in Layout 1, the total material handling distance reduction for the Water Striders:

= 24*1056 + 3*(12*1056/2) (= 44,350 ft.)

= 8.4 miles per month

=100 miles a year

13

Layout 1: Benefits (contd.)

Cost Reduction

Assumption: Speed of cart travel for loaded travel = *0.06 min/ft Time saved by reducing material handling distance = 2660 min per month Considering fully-burdened labor cost @ $ 107/hour, the savings per year gained by reducing material handling distance travelled by the two Water Striders = (2260/60 * 107)*12

= $ 56,925

14

Layout 1: Benefits (contd.)

Lead Time Reduction

By reducing the travel distance between two consecutive work centers that process a job, there is an implicit assumption that current Lead Time between those two work centers can be reduced by 20% - 50%

Job completes at FROM work center

Job picked up by Water Strider

Job arrives at TO work center

Job starts at TO work center

Job completes at TO work center

Current Lead Time between consecutive operations

Any Lead Time reductions gained from changes in the factory layout will require the following projects to be successfully implemented: Job scheduling Improving factory logistics using Water Striders

15

Layout 1: Benefits (contd.)

The 2015 data for completed New screws was used because E1 does not have data clocked for New screws. Based on this data, the current Average Lead Time for a set of New screws ≈ 117 days (= 16.7 weeks including weekends)

Using the Estimated Lead Time Reductions shown in the table, Layout 1 has the potential to reduce Average Lead Time for a set of New screws by 11 days (= 1.6 weeks)

Departments Current Lead Time

(Days) Estimated Lead Time

Reduction

Blank OD ↔ Straightener 3.4 50%

Straightener ↔ HOB 1.3 50%

CNC ↔ Straightener 3.3 50%

Straightener ↔ Simulation 1.3 50%

Polish ↔ Straightener 4.5 50%

Straightener ↔ Inspection 2.7 50%

Nitride ↔ Straightener 2.0 50%

PTA ↔ Straightener 1.1 20%

Straightener ↔ Grind 2.8 20%

Lead Time Reduction (contd.)

Layout 1 will reduce the total time that any set of New screws spends between the following pairs of work centers:

16

Layout 2

Changes made in Layout 1 to realize this new layout:

Move Thread Mills 1, 2, 3 & 4 to the SW corner of the factory

Move PBR Lathe next to the current location of Thread Mill 1

Move Hob to the current location of Thread Mill 2

Move North TOS Lathe to the current location of Thread Mill 4 to create a cell that

includes Saw, Core Drill, East TOS, West TOS, North TOS and PBR Lathe.

Move Welding department below Polishing

Move VDF Lathe to the current location of Welding department

Consider future Cap.Ex purchases:

CNC grinder put next to the Shipping department

Small CNC Lathe with live tooling to replace Daewoo, Bridgeport & Webb Lathe

Move G4 to the current location of the North TOS Lathe

17

BOXING & ASSEMBLY

FINISH INSPECTION

MAGNAFLUX

WEINGARTNER

COBURG 1COBURG 2

MAZAK

PBR LATHE

MORI NT6600

SM C

INC

INA

TI

(G4

)

NEW SMTW (G5)NORTON GRINDER (G7)

TANK NEUTRALIZE

MASK

BLAST

STEL

LITE

PTA

1

STEL

LITE

PTA

2

WIRE WELD

SPRAYCORE DRILL TOSS LATHE

N TOSS LATHE

SAW

PO

LOSH

BO

OTH

S

PRESS

MAINTENANCE

HOB MACHINE

SHARP MILL

SHARP LATHE

WE

BB

LA

TH

E

TARNOW LATHE

BRIDGEPORT

DAEWOO

TOSS LATHE

PA

RA

LLELSIM

SAN

D

BLA

ST

CONICAL SIM

VDF LATHE

OV

EN

EITEL PRESS

WIR

E W

ELD

BARREL INSPECTION

TM1

TM2

TM3

TM4

CNC Grinder

Small CNC lathe with live tooling

Layout 2: Improvements over Layout 1

Raw material enters through here

Re-located Machines/ Departments

* Diagram is not to scale, kindly refer AutoCAD version

Grinding department 1: Dedicated to grinding operations for the Weingartner and those done after Nitride process

Grinding department 2: Dedicated to grinding operations before Nitride process

18

Layout 3: Ideal Flow With Current Equipment 75'-0"

18'-

10 1

/2"

ASSEMBLY

FINISH & BARREL

INSPECTION

Magnaflux

Weingartner

CO

BU

RG

1C

OB

UR

G 2

MAZAK

PBR LATHE

MORI

G1

G2

G3 G4

G5

G6

G7

Tank Neutralize

TM1TM2

TM3 TM4

MASK

BLAST

PT

A1

PT

A2

WELD

SPRAY

CORE DRILL

W TOSS LATHE

N TOSS LATHESA

W

PO

LIS

H B

OO

TH

S

PRESS P1

Maintenance

HOB MACHINE

SHARP MILL

SHARP LATHE

WE

BB

L

AT

HE

TA

RN

OW

L

AT

HE

BRIDGEPORTDAEWOO

E TOSS LATHE

BL

AS

T

CO

NIC

AL

SI

MU

LA

TIO

N

VD

F L

AT

HE

PA

RA

LL

EL

SIM

UL

AT

ION

OV

EN

EITEL PRESS

WE

LD

NEW SIM

NEW PRESS

16'-0"

Added 3rd Straightener

Added 3rd SIM station

* Diagram is not to scale, kindly refer AutoCAD version

19

Layout 3: Ideal Flow VS Current Flow

ASSEMBLY

FINISH & BARREL

INSPECTION

Magnaflux

Weingartner

CO

BU

RG

1C

OB

UR

G 2

MAZAK

PBR LATHE

MORI

G4

G2

G3 G1

G5

G6

G7

Tank Neutralize

TM1TM2

TM3 TM4

MASK

BLAST

PT

A1

PT

A2

WELD

SPRAY

CORE DRILL

W TOSS LATHE

N TOSS LATHESA

W

PO

LIS

H B

OO

TH

S

PRESS P1

Maintenance

HOB MACHINE

SHARP MILL

SHARP LATHE

WE

BB

L

AT

HE

TA

RN

OW

L

AT

HE

BRIDGEPORTDAEWOO

E TOSS LATHE

BL

AS

T

CO

NIC

AL

SI

MU

LA

TIO

N

VD

F L

AT

HE

PA

RA

LL

EL

SIM

UL

AT

ION

OV

EN

EITEL PRESS

WE

LD

NEW SIM

NEW PRESS

16'-0"

ChromeNitride

MCP159ASMASSEMBLE SCREWS, BOX SCREWS, SHIP

SCREWS

MCP150INS FINISH INSPECTION

MCP150MAG MAGNAFLUX

MCP151C4WEINGARTNER

MCP151C1COBURG 1

MCP151C2COBURG 2

MCP151C3MAZAK

MCP151C6PBR LATHE

MCP151C7MORI NT6600

MCP153G5 NEW SMTW

MCP153G7NORTON GRINDER

MCP150TNKTANK NEUTRALIZE

MCP152TM1HECKERT CC

MCP152TM2HECKERT AH

MCP152TM3HECKERT FH

MCP152TM4HECKERT AH

MCP154MSKMASK

MCP154BLTBLAST

MCP154PT1STELLITE PTA1

MCP154PT2STELLITE PTA2

MC

P1

54W

LDW

ELD

MCP154SPRSPRAY

MCP155CD1CORE DRILL

MCP155ML2W TOSS LATHE

MC

P1

55M

L3N

TOSS LA

TH

E

MCP155 SAW

MC

P1

56P

OL

PO

LISH B

OO

TH (7

)MCP155P1

PRESS

MAINTENANCE

MCP155HM1HOB MACHINE

MCP

155M

3SH

AR

P

MILL

MCP

155M

L6SH

AR

P LA

THE

MCP

155M

L5W

EBB

LATH

EM

CP15

5ML4

TAR

NO

W LA

THE

MCP155M2BRIDGEPORT

MC

P1

51C

5D

AEW

OO

MC

P1

55M

L1E TO

SS LATH

E

MC

P150

SIM

PA

RA

LLELSIM

ULA

TION

MC

P1

54B

LTB

LAST

MCP150SIMCONICAL

SIMULATION

VDF LATHE

OV

EN

MCP155P2EITEL PRESS

MCP154WLDWELD

PRE-INSPECTION

BARREL INSPECTION

ChromeNitride

Routing was mapped for New Tungsten Medium-size screws

Layout 3 Current State

20

Layout 3: Ideal Flow VS Current Flow

Routing was mapped for Rebuild Tungsten Medium-size screws

Layout 3 Current State

75'-0"

18'-

10 1

/2"

ASSEMBLY

FINISH & BARREL

INSPECTION

Magnaflux

Weingartner

CO

BU

RG

1C

OB

UR

G 2

MAZAK

PBR LATHE

MORI

G4

G2

G3 G1

G5

G6

G7

Tank Neutralize

TM1TM2

TM3 TM4

MASK

BLAST

PT

A1

PT

A2

WELD

SPRAY

CORE DRILL

W TOSS LATHE

N TOSS LATHESA

W

PO

LIS

H B

OO

TH

S

PRESS P1

Maintenance

HOB MACHINE

SHARP MILL

SHARP LATHE

WE

BB

L

AT

HE

TA

RN

OW

L

AT

HE

BRIDGEPORTDAEWOO

E TOSS LATHE

BL

AS

T

CO

NIC

AL

SI

MU

LA

TIO

N

VD

F L

AT

HE

PA

RA

LL

EL

SIM

UL

AT

ION

OV

EN

EITEL PRESS

WE

LD

NEW SIM

NEW PRESS

ChromeStrip

16'-0"

MCP159ASMASSEMBLE SCREWS, BOX SCREWS, SHIP

SCREWS

MCP150INS FINISH INSPECTION

MCP150MAG MAGNAFLUX

MCP151C4WEINGARTNER

MCP151C1COBURG 1

MCP151C2COBURG 2

MCP151C3MAZAK

MCP151C6PBR LATHE

MCP151C7MORI NT6600

MCP153G5 NEW SMTW

MCP153G7NORTON GRINDER

MCP150TNKTANK NEUTRALIZE

MCP152TM1HECKERT CC

MCP152TM2HECKERT AH

MCP152TM3HECKERT FH

MCP152TM4HECKERT AH

MCP154MSKMASK

MCP154BLTBLAST

MCP154PT1STELLITE PTA1

MCP154PT2STELLITE PTA2

MC

P1

54W

LDW

ELD

MCP154SPRSPRAY

MCP155CD1CORE DRILL

MCP155ML2W TOSS LATHE

MC

P1

55M

L3N

TOSS LA

TH

E

MCP155 SAW

MC

P1

56P

OL

PO

LISH B

OO

TH (7

)

MCP155P1PRESS

MAINTENANCE

MCP155HM1HOB MACHINE

MCP

155M

3SH

AR

P

MILL

MCP

155M

L6SH

AR

P LA

THE

MCP

155M

L5W

EBB

LATH

EM

CP15

5ML4

TAR

NO

W LA

THE

MCP155M2BRIDGEPORT

MC

P1

51C

5D

AEW

OO

MC

P1

55M

L1E TO

SS LATH

E

MC

P1

50

SIM

PA

RA

LLELSIM

ULA

TION

MC

P1

54B

LTB

LAST

MCP150SIMCONICAL

SIMULATION

VDF LATHE

OV

EN

MCP155P2EITEL PRESS

MCP154WLDWELD

PRE-INSPECTION

BARREL INSPECTION

ChromeStrip

21

Layout 4: Two Separate Focused Factories

Current State for New, Coating & Rebuild screws

22

Current State for only New & Coating screws

Layout 4: Two Separate Focused Factories (contd.)

23

Current State for only Rebuild screws

Layout 4: Two Separate Focused Factories (contd.)

Shared Resources: Straightener Press Grinders Welding Mask Spray Blast Thread Mills TOS Lathe Simulation Stations Polishing

24

Why Separate Focused Factories is NOT Advisable

Current machines do not have the flexibility to carry out all operations

(ex: all existing grinders cannot perform all the different operations)

Duplicating all of the shared resources requires significant CapEx

Additional manpower will have to be hired

Neither the resources nor the manpower will be at full utilization

Current factory will have to be expanded to implement both focused

factories