Stephens Valve Company Production Simulation

You are a manufacturing company in a competitive market. The product you make has three variants. The lower valve body is either red, yellow or blue.

Completed Valve Assembly

Controller /Mount Assembly

Valve Body Assembly End Fitting

Valve Mount Assembly

Controller

Lower Valve Body

Upper Valve Body

Flange

Extrusion

The customer requires you to produce to a TAKT of 15 seconds You have been given a factory layout and you must work to this for round 1. What are your objectives for this business? There will be further rounds where you will be expected to make improvements. At the end of round you must measure: Inventory Finished Goods, Work in Process (control part only) Quality Internal, at the customer Delivery To the customer Customer Satisfaction Will he give us new business? Employee Satisfaction

Stephens Valve Company Production Simulation

You are required to take role in the factory as follows: 4 operators 2 material handling 1 quality 1 planning 1 plant manager 1 customer 1 observer, process improvement consultant After each round you will have 10 minutes to a) plan priority actions and b) implement the actions. You must finish a) before starting b). For Round 2 the TAKT reduces to 10 seconds. For Round 3 you must quote the lowest TAKT and prove with a run at rate. Required Materials: lego materials with a quality checkpoint Customer checksheet for delivery ( run for 20 pieces and check quality and delivery for each piece) MRP system Roll a Dice to get colour of finished product

1,2 = red 3,4 = yellow 5,6 = blue

Factory layout: Batch Size 5 Operation 2 Batch Size 5 Operation 3

Customer

Batch size 10 Operation 1 Operation 4