ACME STAMPING DATA SET
Acme Stamping Company produces several components for vehicle assembly plants. This case concerns one product family, a steel instrument-panel bracket subassembly in two types: one each for left-hand and right-hand drive versions of the same automobile model. These components are sent to the State Street Vehicle Assembly Plant (the customer) Production Processes Acmes processes for this product family involve stamping a metal part followed by welding and subsequent assembly. The components are then staged & shipped to the vehicle assembly plant on a daily basis. Switching between Type LH (left-hand-drive) brackets requires a 1 hour changeover in stamping and a 10-minute fixture change in the welding processes. Steel coils are supplied by Michigan Steel Co. Steel deliveries to Acme arrive on Tuesdays and Thursdays. Customer Requirements 18,400 pieces per month (12,000 per month of Type LH & 6,400 per month of Type RH). Customer plant operates on two shifts. Palletized returnable tray packaging with 20 brackets in a tray and up to 10 trays on a pallet. The customer orders in multiples of trays. One daily shipment to the assembly plant by a truck. Work Time 20 days in a month Two shift operation in all production departments Eight (8) hours every shift, with overtime if necessary Two 10-minute breaks during each shift. Manual processes stop during breaks. Unpaid lunch Acme Production Control Department Receives State Streets 90/60/30-day forecasts and enters them to MRP. Issues Acme 6-week forecast to Michigan Steel Co. via MRP. Secures coil steel by weekly FAXed order release to Michigan Steel Co.. Receives daily firm order from State Street Generates MRP-based weekly departmental requirements based upon customer order, WIP inventory levels, F/G inventory levels, and anticipated scrap and downtime. Issues weekly build schedules to Stamping, Welding, and Assembly processes. Issues daily shipping schedule to shipping Department. Process Information All processes occur in the following order and each piece goes through all processes 1. Stamping (The press makes parts for many Acme products) Automated 200 Ton press with coil (automatic) material feed Cycle Time: 1 second (60 pieces per minute) Changeover time: 1 hour (good piece to good piece) Machine reliability: 85%
Observed Inventory: o 5 days of coils before stamping o 4,600 pieces of Type LH finished stampings o 2,400 pieces of Type RH finished stampings 2. Spot Weld Workstation I (dedicated to this product family) Manual process with one operator Cycle time: 39 seconds Changeover time: 10 minutes (fixture change) Reliability: 100% Observed Inventory: o 1,100 pieces of Type LH / 600 pieces of Type RH 3. Spot Weld Workstation II (dedicated to this product family) Manual process with one operator Cycle time: 46 seconds Changeover time: 10 minutes (fixture change) Reliability: 80% Observed Inventory: o 1,600 pieces of Type LH / 850 pieces of Type RH 4. Assembly Workstation I (dedicated to this product family) Manual process with one operator Cycle time: 62 seconds Changeover time: none Reliability: 100% Observed Inventory: o 1,200 pieces of Type LH o 640 pieces of Type RH 5. Assembly Workstation II (dedicated to this product family) Manual process with one operator Cycle Time: 40 seconds Changeover time: none Reliability: 100% Observed Finished-Goods Inventory in Warehouse: o 2,700 pieces of Type LH o 1,440 pieces of Type RH 6. Shipping Department Removes parts from finished goods warehouse and stages them for truck shipment to customer.
