BASE-FRAME DESIGN OPTIMIZATION

BASE-FRAME DESIGN OPTIMIZATION

BASE-FRAME DESIGN OPTIMIZATION
PROJECT DELIVERABLES
PROJECT DELIVERABLES
S. ZIA UL HAQ & SONS
PRINCIPLES OF LEAN MANUFACTURING
LEAN MANUFACTURING
SZS
IMPLEMENTING LEAN MANUFACTURING
PRINCIPLES AT A MANUFACTURING COMPANY
DEPARTMENT OF INDUSTRIAL & MANUFACTURING ENGINEERING
SHOAIB IQBAL, MUFAZZAL, FAISAL NAJM, SALMAN AHMED JILANI
Batch 2009-2010
LEAN MANUFACTURING
A comprehensive set of techniques that, when united together,
will allow the reduction and then elimination of the seven
wastes:
SZS, a private sector ISO 9001:2000 certified organization, is
engaged in different domains as sighted below:
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Catering
Portable Cabins
Camp Management
Services
Manpower Supply
Civil Engineering
HVAC
1. Waiting
2. Over Production
3. Rejects
4. Excess Motion
Specify what creates value
Identify all the steps along the process chain
Make those processes flow
Make only what is pulled by the customer
Go for precision by repeatedly removing wastes
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Reduction of Wastes &
Productivity
Improvement
Through improving
operations
Through making
Improvements in the
design
Through making
enhancements in the
Layout
BASE-FRAME DESIGN OPTIMIZATION
PRINCIPLES OF LEAN MANUFACTURING
S. ZIA UL HAQ & SONS
PROJECT DELIVERABLES
WASTE ANALYSIS
0
20
40
60
80
100
120
Wastes
Frequency
Roof Frames fabricated
at the ground
TOOLS UTILIZED
Material pre-cut
at the store
Specialized Workers for
major operations
LAYOUT ANALYSIS & ENHANCEMENTS
2
3 Pulley
Mechanism
7
4
1 Retractable Awning
8 Proposed Design of Cart
6 Towing Car for transportation
5 Fixtures and Clamps
9 Pneumatic Riveter
12
Dr. M. Fahad (Associate Professor)
Ms. Rabia Zubair (Lecturer)
Mr. Azhar Qadri
(Manager Engineering, SZS)
Internal
Advisors:
External
Advisor:
Equipment
On-spot
Sizing
Inappropriate
Cart Height
Fabrication at
altitude
Work overload
Manual Material
Lifting
Exposed
Manufacturing
Floors
Environment
Waste
Time &
Resources
Large distance
between work and
storage area
Manual
Riveting
Manual Material
Transfer
Transportation Operations
Current Design and Analysis of Base frame
Proposed Designs of Base frame
Proposed solutions for reduction of wastes
Base Frame Design Optimization:
Waste Analysis & Elimination:
Layout Designing & Improvement:
NX 7.5, ANSYS v14
WBS
Time & Motion Study
Quality Tools
Kaizen
5S
AutoCAD 2010
5. Over Processing
6. Excess Inventory
7. Transportation
Current Layout of Manufacturing yards
Current Proposed
Distance 310.5 meters ~ 240 meters
Time 3.33 hours ~ 2 hours
Proposed Layout of Manufacturing yards
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
%

R
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Results
Design 1
Design 3 Design 2
Results
Results