Analyse Phase
During the
Analyse phase we looked at the data gathered of the operation hours and
lead-times over a series of completed jobs. We analysed this data in-order to
determine the root cause of the high production costs and long lead-times.
During a
brainstorming session we analysed the average process hours for each operation in
the manufacturing process. We used a cause and effect diagram to pin-point
which process steps have biggest negative and positive influences on the
production cost and lead-times.
The
analysis highlighted the negative effect CNC milling had on the manufacturing
process. The CNC Milling operation is both labour intensive and leads to the
requirement of other operations later in the manufacturing process. Wire EDM
erosion on the other hand is not labour intensive and produces finished
components which reduces the requirement of other operations later in the
process. Another advantage of the Wire EDM process highlighted was an ability
to run lights out which would have a positive effect on both production costs
and lead-times. It was also evident that the design operation had major
influence on how each job passed through the manufacturing process.
The
analysis highlighted that a reduction in the CNC Milling operation by
increasing the use of the Wire EDM Erosion operation would have a positive
effect on both production costs and lead-times.
