Using the Lean Principles as a framework, what improvements do youconsider that the management team at Aylesbury should be giving priority to,and why?
Aylesbury Pressings is a manufacturing company that producesautomotive metal components that supplies the automobile industry. Thebusiness displays characteristics of a high volume high variety operationas its’ products are considered runners or repeaters with batch ranges of between 150-500 parts and a variety of 80 main products many of whichhave several versions. This complex environment posses some difficultchallenges for the Aylesbury Pressings operation. Many of the difficultiesfaced by Aylesbury Pressings can be alleviated
by using some techniquesassociated with lean manufacturing.
The Lean philosophy identifies seven different forms of waste (muda),these are over production, waiting time, transport, process, inventory,motion and defectives. One obvious source of waste in the operation is inthe production of defectives in the pressing stage of operations. Many of the dies used are old and difficult to adjust which results in defectivematerials being produced. These dies should be replaced or upgraded(subject to cost benefit analysis) as a matter of urgency and should be thefirst priority of the management team. This is so because if the output of this early stage of production is of a high quality and the process itself controlled, it will make all subsequent stages of production much easier toimprove as the supply of materials to these stages will be morepredictable and of higher quality. Quality, right first time does not seem tobe a major priority for Aylesbury pressings as only 4 of the 280 staff areactually employed doing quality work. There has been a reduction in the defect rate from 40,000 parts permillion to 1600 parts per million; however this is after a 5% - 13% of product has been reworked – this is Quality Control not Quality Assurance.All rework is non value add and therefore a waste in lean terms. Apartfrom the waste in resources it also adds uncertainty to scheduling andencourages/condones keeping large volumes of WIP to compensate.Rework reduction would be an ideal project for the new Black belt.
Involvement of all staff: