Production Line Simulation
Not Required
FinalProject-Group-3WEEKSInstructionsR20241.pptxManufacturing Leadership
FINAL PROJECT – Production Line
1
Now that you have learned and developed the necessary leadership skills and technical problem-solving skills, it’s time to start running and managing your very own production cell!
This project will have you work together in groups to practice and demonstrate your leadership skills and team decision making in a 3 to 4-week production simulation during our regular class time that will involve daily team huddles, assigning resources, data collection, data monitoring, and data reporting on your production performance. (i.e. applying the concepts learned in MGMT8670). Improvement methods that were discussed in class are expected to be applied to improve performance of your production line.
The final week of this project will have each team present their results, findings, and interesting things learned throughout.
Here’s how to accomplish this, stay on track, and earn the grades!
Week 10, will be “Day-1” setting up the “initial/current state” production (worth 10% of your grade):
“SETUP” and “PLAN” your production team and production cell. You will need workers, a QC person, and a leader/supervisor. You will be given an area of the classroom for which you are free to arrange the resources you need (desks, chairs, tables, bins, people, flow, etc.) in order to “RUN” your Day-1 production. Day-1 will represent what’s known as your “initial/current state” production process.
Week 11 and 12 will be dedicated to apply improvements to original set-up, measure productivity and improvement progress and be ready in week 12 to run a full scale production.
Project Details – Outputs and successes include:
All team members in attendance and participating
All team members have a role to play, and have fulfilled that role during the simulation
You must measure, record, and report out upon the following KPIs:
1. Throughput (units/min)
2. First Time Yield (FTY)
3. WIP (units in process)
4. Productivity (min/unit)
5. Direct vs. Indirect Labor ratio
Project Details – Outputs and successes for Day-1 (worth 10% of your mark):
A team huddle occurs prior to production run (led by team leader/supervisor)
Receive instructions on the product specifications and BoM
Day-1 production performance data has been collected somehow (paper, pen, or digital)
Day-1 informal report out to Plant Manager (Faculty). What is going well/not well, doubts needing clarified, etc. (24 hours after class)
Observe, document, take/make notes about anything you may want to use/share for your final presentation (final report out in week 15)
Production supplies returned to warehouse
Classroom tidied up and returned back to its original state
Depending on our successes and challenges, we may need to run production twice for Day-1. Plant manager will decide.
MGMT8670 Project Details – DAY 1 In Class Preparation and Work:
Group planning and decision making to production run. You will have about 60 to 70 minutes to complete the following:
Assign specific LEADERSHIP ROLES to each team member: Operational Leader, Team Huddle Leader, KPI Leader, Kaizen (improvement) Leader, Auditor/Notetaker (do not confuse auditor and inspector) – explain why the specific role (max 1 point)
Create a LSW (leader standard work) document for each leader (max 2 points)
Prepare an agenda and hold Team Huddles – communication, motivation (max 2 points)
Decide the metrics needed to be collected from the production line (explain) and create the template dashboard to be used throughout the project (max 2 points)
First attempt to production line set-up (initial/current state) (max 3 points)
Informal verbal report out (in class) to your Plant Manager (Faculty) what goes well, challenges, help needed
Within 24 after class ends, group submits any document created in the Project Folder for proper scoring of class activities.
Make any notes your group may need to use later on to create your final report out, including observations about leadership styles, personalities, etc. Notes from each week are key to final presentation preparation.
Depending on our successes and challenges, we may need to run production twice for Day-1. Plant manager will decide.
Project Details – Day-1 BOM (Bill of Materials)
Fig. 1 FINAL PRODUCT
Fig. 2 BOM
END OF DAY 1 TO BE CONTINUED
Your team will be tasked with “IMPROVING” your production process to meet a new level of demand (i.e. a new/higher production quota). Can you achieve this new production quota? What improvements/changes do you need to make in order to achieve this new production quota? This week will be dedicated to brainstorming, and making change for the better (kaizen …).
Outputs and successes for Day-2 include:
All team members in attendance and participating
Video capture (recording) from Day 1 is available/ready for team review during this week
Team Huddle
Several (multiple) process improvement ideas established (max 1 point); and
Top/best process improvement ideas selected and physically tested in time for the next production run and pilot run or trials conducted to validate success and practice new (changed) processes, techniques, or tools. Improved, optimized, balanced production line is ready to run (desired state = new process set-up) to meet new/higher production quota (max 2 points);
Dashboard updated (max 2 point)
Depending on our successes, challenges, ideas, and implementation progress this week, groups may decide to pilot/run production in week 3 (Day-3) instead. TBD by plant manager and groups.
Project Details –
Week 11 is “Day-2” PRODUCTION LINE IMPROVEMENT (worth 5% of your final grade)
9
END OF DAY 2 TO BE CONTINUED
This week will be used for piloting and running production based on the improvements/ideas/setups arrived at during Day-2. The goal for this week is to setup your improved state production process and resources, and then run production to achieve the target production quota.
Outputs and successes for Day-3 include:
All team members in attendance and participating
Top/best process improvement ideas from Day-2 are implemented
A team huddle occurs prior to production run (0.5 points)
Production run delivers on the throughput target (max 1.5 points)
Production monitoring of KPIs takes place (max 1.5 points)
One last improvement (final desired state) of performance has been achieved (max 1.5 point)
BUILD SOME FUN INTO IT
Project Details –
Week 12 will be “Day-3” FULL PRODUCTION RUN + FINAL IMPROVEMENT(worth 5% of your grade)
TARGET
25
pens/group
END OF PROJECT TO BE CONTINUED – FINAL PRESENTATION
