Page 191 - FLL Virtual Binder 2018

Sky View Industries Problem Solving Case Study Application Activity
Situation
Sky View Industries produces propeller assemblies for the airplane industries. Their demand is currently 1,000 propeller assemblies per day. They currently produce 5 different models utilizing one assembly line. The main production line is made up of 4 operations: stamp, press, weld and assembly. Each operation is utilized in the production of all models. The total yield for the production line is currently 62%.
In order to improve yields, Sky View Industries has assembled a Continuous Improvement Team focused on this issue. The team is comprised of employees from each of the operations.
Information
The following information, collected from previous brainstorming is available for each of the operations.
Stamp
• Stamping is the first operation and has a 85% Yield
• Raw material, in the form of coiled steel, is released into the operation in a lot size of two coils
which is enough for 3000 pieces.
• Raw Material is required to have tight tolerance which is above the raw material industry standard.
• The stamping equipment is approximately 25 years old. The manufacturer for this equipment is no longer in business.
• The change over time is 90 minutes. Set-up is done by maintenance department due to the size of the dies and lack of equipment.
Press
• Press is the second operation and has a 95% Yield
• The change over time is 30 minutes.
• Press is in a different building than the stamp operation. Work in process is transported via lift truck outside between buildings.
• Tooling for Press is approximately 10 years old.
• Press operators are responsible for maintaining their own tooling. Weld
• Weld is the third operation and has a 90% Yield
• Change over time is 30 minutes.
• Welding Equipment is 2 months old.
• Welding is in the same facility as stamping.
• Welding is responsible for making its own fixtures for manufacturing.
• Numerous changes in welding engineering specifications. Assembly
• Assembly is the fourth operation and has an 85% Yield Front Line Leadership Module: Culture and Change
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