Name: Chandra Mani

Case Study No :02

Resolving the recurring problem with the MES software and ensuring smooth production operations
involves a systematic approach that addresses both the technical issues with the software and the
communication challenges between the production team, IT team, and any other relevant
stakeholders. Here's a step-by-step plan to address the issue:

1.Immediate Response:

 Acknowledge the seriousness of the issue raised by the production team leader during the
meeting.
 Express commitment to resolving the problem promptly and effectively.
 Ensure clear communication channels are established for ongoing updates.

2.Technical Analysis:

 Assemble a cross-functional team including representatives from IT, production, and possibly
external support if needed.
 Conduct a thorough technical analysis to identify the root cause of the software issues.
 Gather detailed information about the specific error messages and malfunctions experienced
by technicians during material issuance and operation completion.

3.Testing and Validation:

 Replicate the reported issues in a controlled testing environment to understand their scope
and severity.
 Validate whether following the existing training material resolves the issues as suggested by
the remote IT team member.
 Document any discrepancies between the expected behaviour outlined in the training
material and the actual performance of the software.

4. Collaboration and Escalation:

 Engage with the software vendor or internal development team responsible for the MES
software to escalate the identified issues.
 Advocate for prioritization of the software fixes based on their impact on production
operations.
 Coordinate closely with IT and other relevant teams to ensure timely implementation of any
necessary patches or updates.

5. Interim Solutions:

 Develop interim workarounds or contingency plans to minimize disruption to production

while awaiting software fixes.
 Provide additional training or resources to production technicians to mitigate the impact of
the software issues on their daily tasks.
6. Communication and Transparency:

 Maintain open and transparent communication channels with all stakeholders, including
regular progress updates and status reports.
 Set realistic expectations regarding timelines for resolution based on the complexity of the
software issues and the availability of resources.

7. Root Cause Analysis:

 IT conducts a thorough analysis of the software issues, including error messages and system
behaviour. Determine if the problems are caused by software bugs, configuration errors, or
integration issues.
 Based on the analysis, prioritize fixes that will have the most significant impact on production
efficiency. Some fixes may require immediate attention while others can be addressed in
subsequent releases.

Best Case Scenario:

 The technical analysis quickly identifies a software bug that can be easily patched by the
development team.
 The vendor or internal development team prioritizes the fix, and a solution is implemented
within a short timeframe.
 Production operations resume smoothly, and the production team is satisfied with the
resolution process and communication efforts.
 Implement a process for ongoing monitoring and evaluation of the MES software
performance.
 Solicit feedback from end-users to identify areas for improvement and prioritize future
software enhancements.
 Proactively address emerging issues and adapt software configurations to meet evolving
production needs.
 Implement software patches or updates to resolve known issues.

Worst Case Scenario:

 The root cause of the software issues is complex and requires significant time and resources
to diagnose and resolve.
 There are delays in communication and coordination between the various teams involved,
prolonging the resolution process.
 Production delays continue to occur, leading to dissatisfaction among customers and
stakeholders.
 Limited availability of IT resources due to competing priorities.
 Inability to identify root causes of software malfunctions.
 Delayed resolution of software issues leading to prolonged production disruptions.
 Communication breakdowns between teams exacerbate tensions and hinder problem-
solving efforts.
 Lack of alignment on priorities and objectives leads to confusion and delays in resolution.
 Lack of follow-up or accountability results in unresolved software issues persisting over time.
  Failure to address underlying systemic issues leads to ongoing production disruptions and
customer dissatisfaction.

Case Study No :03

Given Data:

Required aircraft production rate per year: 60.

Quantity of engines per aircraft: 30(as per engine cavity seen in the picture)
Scrap factor: Unknown
Number of workdays per year: 220.
Shifts per day: 1.
Available work hours per shift: 6.5 hrs

Takt Time and Required Engine Production Rate per Hour:

Takt Time (TT) = Available Production Time per Shift / Required Production Quantity per Shift

Given:

Available work hours per shift = 6.5 hours

Required aircraft production rate per year = 60

Quantity of engines per aircraft = 30

Takt Time (TT) = {(220 workdays/year) * (6.5 hours/workday)}/ {(60 aircraft/year * 30

engines/aircraft)}

Takt Time (TT) = 220 * 6.5 / (60 * 30)

Takt Time (TT) = 1430 / 1800

Takt Time (TT) ≈ 0.794 hours/engine

Required Engine Production Rate per Hour = 1 / Takt Time

Required Engine Production Rate per Hour ≈ 1 / 0.794.

Required Engine Production Rate per Hour ≈ 1.259 engines per hour.

Production Sequence for Final Assembly Line of an Engine:

1. Engine Block Assembly

2. Piston Installation
3. Cylinder Head Installation
4. Crankshaft Installation
5. Camshaft Installation
6. Timing Belt Installation
7. Fuel Injection System Installation
8. Cooling System Installation
9. Exhaust System Installation
10. Final Inspection and Testing

Cycle Time estimation:

Cycle times can vary based on factors such as complexity, automation, and workforce skill
level.

Here are rough estimates:

1. Engine Block Assembly: 30 minutes

2. Piston Installation: 15 minutes
3. Cylinder Head Installation: 20 minutes
4. Crankshaft Installation: 25 minutes
5. Camshaft Installation: 15 minutes
6. Timing Belt Installation: 10 minutes
7. Fuel Injection System Installation: 20 minutes
8. Cooling System Installation: 15 minutes
9. Exhaust System Installation: 15 minutes
10. Final Inspection and Testing: 30 minutes

Lead Time calculation for engine assembly:

Lead Time = Sum of Cycle Times for All Operations

Lead Time = 30 + 15 + 20 + 25 + 15 + 10 + 20 + 15 + 15 + 30 = 195 minutes = 3.25 hours

Analysis: Since the Takt Time is 0.794 hours/engine and the Lead Time is 3.25 hours, the
current production rate meets the required production rate.

To double production, several approaches can be considered:

 Increase work hours per shift: Extend shifts to cover more production time.
 Improve efficiency: Streamline processes, reduce cycle times, and optimize workflow.
 Increase workforce: Hire additional skilled workers to handle increased production.
 Optimize the production process further for efficiency gains.
 Consider investing in additional machinery or technology to increase throughput.

Case Study No :01

Component Work Plan:
Machining Parts

1. Base plate, Roof plate, Distance Washer and Tap support to be machined as per specification
given in drawing.
2. Dimension specification to be checked on actual machined part with help of calibrated
vernier calliper, distance gauge and micrometre.
3. Tolerances to be maintained as per specification given in drawing.
4. All specification given in drawing for machining parts are CC characteristics.
5. Traceability labelling to be done as follows and to pe packed in smooth bubble wrapped
sheet.
Sl. No Part Name Part Number Packaging
1 Base plate T00007548 Foam Bubbled wrap

2 Roof plate T00007549 Foam Bubbled wrap

3 Distance T00006613 Foam Bubbled wrap

washer
4 Tap Support T00007553 Foam Bubbled wrap

Overarching Process:
 1. ME Ops: Project manager responsible for overall coordination and oversight.
2. CAD Designer: Provides technical drawings and design expertise.
3. Technician: Assists with technical analysis and provides input on tool functionality.
4. Procurement Team: Responsible for acquiring any external parts or materials needed.
5. Machinists/Manufacturing Team: Produce components according to the detailed work plans
and technical drawing.
6. Assembly Team: Assemble components into the final tool.
7. Quality Assurance Team: Conducts inspections and verifies compliance with safety and
quality standards.

Process Steps:

1. Review technical drawings and confirm specifications with CAD designer and technician.
2. Develop detailed work plans for components and assembly.
3. Procure any external parts or materials needed.
4. Begin manufacturing of components in-house or externally.
5. Assemble components into the final tool according to the assembly work plan.
6. Conduct quality inspections and testing to ensure compliance with safety and quality
standards.
7. Commission the new tool for use in the production process.
8. Provide training and documentation for operators on the proper use and maintenance of the
tool.

Timeline with Milestones:

 Review technical drawings and confirm specifications: 1 week.

 Develop detailed work plans: 2 weeks.
 Procurement of external parts/materials: 1 week.
 Manufacturing of components: 4 weeks.
 Assembly of components: 2 weeks.
 Quality inspections and testing: 1 week.
 Commissioning of new tool: 1 week.
 Operator training and documentation: Will continue till process matures.

Project Management Approach:

 Regular meetings with all stakeholders to review progress, address any issues or concerns,
and adjust timelines as needed.
 Utilize project management tools such as Gantt charts or Kanban boards to track tasks,
deadlines, and resource allocation.
 Maintain open communication channels to ensure all team members are informed and
aligned on project goals and priorities.
 Anticipate and mitigate potential risks or delays by proactively identifying alternative
suppliers, manufacturing methods, or contingency plans.
 Prioritize safety and quality throughout the project lifecycle, ensuring that all activities
adhere to relevant standards and regulations.
 Document all decisions, changes, and progress updates to provide a clear audit trail and
facilitate knowledge transfer for future projects.