Content area
Full Text
Abstract
Increased product variation, varying line speed, product complexity, and increasing focus on lean manufacturing have led to challenges in the delivery and replenishment of parts in manufacturing processes. Part kitting and sequencing, with a main focus on efficiency in the material flow process, is a good option for manufacturing and assembly operations. This study explores the application of kitting design to improve efficiency in engine preassembly operations at an assembly plant. The study examines the planning process involved in the design of a kitting system and the steps of implementation while developing a fully operational system. The benefits of kitting are reviewed, along with measurements of the impact on assembly operations at the plant.
Keywords
Part kitting, sequencing, product variation.
Introduction
The purpose of this study was to find a practical and cost-effective solution to a problem faced by manufacturing operations at an engine assembly plant. The launch of a new engine variation at the assembly plant created a space issue in the engine line pre-assembly area. The issue specifically regarded parts storage and presentation to support the assembly operation. With three engine types already in production at the time, adding a fourth meant a 25% increase in part content and variation for lineside delivery. At the time, the line configuration was at 90% capacity in the lineside delivery area before launching the forth engine variant. This meant that the current logistics concepts for part replenishment would not support the new engine and an alternative solution was required. Typically in manufacturing, given similar situations, the assembly line is simply expanded to create the space required to support production. However, in an effort to avoid the high investment of line expansion, the goal was to seek alternatives that provided a cost-effective answer to the problem at hand.
As the material flow engineer, with responsibility for the engine line, the team was challenged with the task of developing a system that would allow for the new engine launch without the cost of physical line expansion or an increase in overhead cost due to a greater headcount. This was a unique challenge that required a unique solution. On one hand, the risk associated with downtime for the production line because of missing parts was the ultimate...