April 10, 2024

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 clas

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. (. 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.

Project Details –
Outputs and successes include:

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. Please refer attached document for your refere.

Manufacturing Leadership

FINAL PROJECT – Production Line

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)

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

pens/group

END OF PROJECT TO BE CONTINUED – FINAL PRESENTATION

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Project

Production Line Simulation Day 1

MGMT8670 – MANUFACTURING LEADERSHIP

Presented by

Lino Johnson

Sai Pavan Sagam

Yoganshu Patil

Pranay Bogam

Guided by

Prof. Sorina Andries

Submission Date

03/17/2024

Rev. (i) – 03/26/2024

• Pranay Bogam has been chosen as the Operational and Kaizen Leader due to his

ability to resolve issues swiftly and effectively. He is proactive and excels at

coordinating team members to achieve objectives. His educational background

includes a bachelor’s degree in mechanical engineering from India. His one-year

experience under a production manager has equipped him with valuable insights into

managing production lines, enabling him to make crucial decisions. He is adept at

analyzing production schedules, addressing manufacturing line issues, and has a basic

understanding of Six Sigma and Lean manufacturing.

• Yoganshu, with his adventurous personality, serves as the Team Huddle Leader and

Assembler. His extroverted nature and strong communication skills are instrumental

in fostering team cohesion. He motivates his teammates and builds strong

relationships, contributing significantly to team development. He holds a diploma in

Mechanical Engineering and has gained professional experience as a supervisor at an

automotive company. This experience makes him well-suited for the role, as he is

familiar with the production process and understands product.

• Sai Pavan Reddy Sagam's is chosen as KPI Leader his personality aligns with the

architect type. His background reflects a distinctive mindset, strategic vision, and

extensive design knowledge. Earning a Bachelor of Technology in Petroleum

Engineering and a Master of Science in Supply Chain Management exemplifies this.

Further, his experience as a Supply Chain Analyst at a firm for 2 years and as an

Inventory Management Specialist at another company for 1 year demonstrates his

ability to apply these skills in supervising workflows effectively.

• Experienced in auditing and final assembly, Lino Johnson contributes more than ten

years of global knowledge, especially from architectural projects in Dubai. His

educational background includes a bachelor’s degree in mechanical engineering from

India and he is well-known for his commitment to operational excellence and does

well in demanding settings. Lino demonstrates remarkable problem-solving skills and

has a track record of finishing projects on time and under budget. His responsibilities

include precisely supervising the final assembly process and conducting thorough

audits to maintain quality standards. Lino is a great help in maximising operational

performance because of his drive and leadership.

Leadership Standard Work:

Tasks

Week 1 Saturday

Week 2 Saturday

Week 3 Saturday

Raw Material

N/A N/A

Team Meeting

N/A N/A

Inspection of

raw material

N/A N/A

Line setup

N/A N/A

Distribution of

Raw material

N/A N/A

Gemba Walk

N/A N/A

Recording of

time and data

of production

N/A N/A

Collect and

Analyze KPI

Data

N/A N/A

Documentation

and Final

Report

N/A N/A

Meeting with

Plant Manager

N/A N/A

1. Discuss process starting and production responsibilities.

2. Talk with the team regarding the product.

3. Consult the team on assembly line configuration.

4. Provide assembly manuals for the product.

Team Huddle Agenda

Tasks Location Time

Pranay

Bogam

(Operational

& Kaizen)

Yoganshu

Patil

(Team

Huddle)

Sai

Pavan

Reddy

Sagam

(KPI

Leader)

Lino

Johnson

(Auditor)

Raw Material

Classroom (GU-GMB-

E8) 13:00

Team Meeting Classroom (GU-GMB-

E8)

13:05

Inspection of

raw material Classroom (GU-GMB-

E8) 13:15

Assigning

Operators Classroom (GU-GMB-

E8) 13:20

Distribution of

Raw material Classroom (GU-GMB-

E8) 13:28

Gemba Walk Classroom (GU-GMB-

E8) 13:40

Documentation

and Final

Report Classroom (GU-GMB-

E8)

14:00

Meeting with

Plant Manager Classroom (GU-GMB-

E8) 14:15

• DIRECT & INDIRECT LABOUR

DIRECT & INDIRECT LABOUR (3:5)

Direct Labour Indirect Labour

Operator 1 Operational Leader

Operator 2 Kaizen Leader

Assembler Auditor

KPI Leader

Team Huddle

1) First-time Yield: (number of good parts/numbers of total products) *100

= (3/3) *100

= 100

First-time yield of 100%

Day Number of units

Produced

Time

(min)

Quantity

good Rejection Reworked FTY

DAY 1 3 1.40 3 0 0 100.00%

DAY 2

DAY 3

KPI DAY 1 DAY 2 DAY

Improvement

First time yield (FTY) =

(quantity good / quantity

produce) *100

(3/3) *100 =

100%

Throughput = total number of

units/ total time (units/sec) 0.04

WIP (unit in process) 0

Productivity = total time taken /

unit produced 33.333

1. Rubber Grip

2. Upper Casing

3. Tip

4. Spring

5. Refill

6. Upper Part

7. Thrust Device

8. Lower Casing

Workstation 1

Workstation 2

Workstation 1

1. Rubber Grip 2. Upper Casing ( Sub-Assembly 1) 3. Tip 4. Upper Part 5.

Workstation 2

1. Spring 2. Refill (Sub-Assembly 2) 3. Thrust Device 4. Lower Casing

Workstation 3

Combining and tightening subassembly 1 & 2.

Assembly Flow Chart: (DAY 1)

Day-2” PRODUCTION LINE IMPROVEMENT

Team Huddle Agenda

Tasks Location Time

Pranay

Bogam

(Operational

& Kaizen)

Yoganshu

Patil

(Team

Huddle)

Sai

Pavan

Reddy

Sagam

(KPI

Leader)

Lino

Johnson

(Auditor)

Raw Material

Classroom (GU-GMB-

E8) 13:00

Team Meeting Classroom (GU-GMB-

E8)

13:05

Inspection of

raw material Classroom (GU-GMB-

E8) 13:15

Assigning

Operators Classroom (GU-GMB-

E8) 13:20

Distribution of

Raw material Classroom (GU-GMB-

E8)

13:28 –

13:30

Gemba Walk Classroom (GU-GMB-

E8)

13:40 –