Abstract:
The project objective is to reduce the waste in different aspects in an automotive feeding
factory. One of the wastes is generated from the sheet cutting process, in which the sheet
is cut into specific pattern of one product type, which leads to a huge waste of material.
One more waste is observed in the welding station. The incorrect procedure of welding
task generates the poor quality waste in the final product. Moreover, there are seven
grouped press machines that used for manufacturing the variety of products, with an
average 45 minutes for every setup on each machine, which has a huge impact on the
machine availability.
The project will emphasize how a developed report was used to implement a linear
programing approach, in which the waste was reduced from 1.1% to 0.43%. Plus, it will
highlight the training program, which underlined the welding basics and the handling of
standardization sheets that was developed to improve the worker efficiency from 83% to
87%. Also, the project will highlight the implementation of Single Minute Exchange of
Die (SMED) that lead to reduce the changeover time by 38%. In addition, using the best
fitting forecasting technique, the market demand for the coming quarters are forecasted
to define different scenarios. Thus, a proposed scheduling optimization model was
developed to be implemented to increase the press machines efficiency and reduce the
needed working hour by 14%. Finally, the market demand will be forecasted, and the
project will discuss the factory incremental improvement S-curve, in which the need of
innovation is recommended.