Assignment 2: Evenort Case Study

Contents
Assignment 2: Evenort Case Study 1
Scenario 2
Context 3
General Company Background 3
The Production Process 3
Examples of typical products (flanges). 4
Facility Layout 5
Product route 6
Current Value Stream Map 8
Appendix 9
Current Value Stream Map 15
Flange Production: Saw Cutting Process Data 16
Administrative Process 17

Table of Figures
Figure 1 Aerial photograph of Evenort. (Building with white roof.) 2
Figure 2 0.75" Diameter Flange 4
Figure 3 16" Diameter Flange 4
Figure 4 Shop Floor Layout. 5
Figure 5 Production Route 1 6
Figure 6 Manufacturing Process and Product Route. 7
Figure 7 Current Value Stream Map 8
Figure 8 Product Route 1 10
Figure 9 Product Route 2 11
Figure 10 Product Route 3 12
Figure 11 Product Route 4 13
Figure 12 Some ideas for improving the site 15

1
Scenario

Manufacturing and logistics industries involve the movement of physical items

through a series of processes and acted upon by discrete resources. Being aware
that industry is under constant pressure to provide high quality, timely products while
utilising the minimum of resources you are required to research and apply
appropriate Lean Tools and techniques within Evenort, a small manufacturing
business situated based in South Yorkshire. Thereby helping the business better
identify and remove waste. Below, Figure 1, is an aerial photograph of Evenort's
premises. It should be noted from the photograph that there is little room for
expansion as there is a train track behind the factory and buildings on either side. It
may be possible to extend the building towards the main road if required.

Figure 1 Aerial photograph of Evenort, (The building with the white roof).

2
Context

Evenort, an SME based in South Yorkshire, and is seeking to increase efficiency

within the business through implementing a process improvement strategy. In
conjunction with Sheffield Hallam University a Knowledge Transfer Partnership was
entered into providing the opportunity to change. Lee, the Knowledge Transfer
Associate having an awareness of Lean, 6 Sigma, and discrete-event simulation has
the opportunity to make significant improvements to the bottom line of the business;
but before making any change to the business he must first identify what
improvements could be made and devise a strategy for making those improvements.
What could, where would you, and in what order would you implement changes?
Make your recommendations.

General Company Background

Incorporated in Sheffield in 1982, Evenort is currently situated over two sites. The
Head Office and main manufacturing site is at Houghton Road, Dinnington, Sheffield,
S25 4JJ, UK. With its plasma cutting workshop based at: Shop 12, Robert Jenkins
Works, Wortley Road, Rotherham, S61 1LT, UK.

Evenort's commitment to manufacturing excellence has established the company as

a reliable partner in the processing of Stainless Steel. Evenort's business
proposition is to supply high value bespoke products, typically flanges, produced
within 24hours of order, to the highest quality standards and manufactured from
alloys appropriate to the environment, be it sour or acidic. As such their products are
often used in the oil and gas industries.

The Production Process

Evernort offers a range of products and services which includes:

● Steel & Alloy Flanges
● Bar Processing
● Advanced Manufacturing
● Deep Water Shipments
● Plasma Cutting

However, the focus of this case study is Evenort's Head Office where flanges are
machined, either from cut bar or semi-finished forgings.

Semi-finished forgings are usually purchased from Hilton Metal Forging Ltd. based in
India, of whom Evenort owns a substantial share of and is the official UK agent.

3
Examples of Typical Products (Flanges).

The flanges come in a variety of sizes but typically range in size from 98mm Dia to
597mm Dia and are manufactured from stainless steel. Figure 2 and Figure 3 illustrate
and provide schematics of the products.

0.75" ASA 150LB RFSO 316/L

Dimensions in mm

No.Hole
D K L C N H B R O F
s
9 69. 15. 12. 3 15. 27. 42. 1.
3 4
8 8 9 7 8 9 7 9 6
Figure 2 0.75" Diameter Flange

16.00" ASA 150LB RFSO 316/L

Dimensions in mm

D K L C N H B R O F No.Holes
597 539.8 28.6 36.5 457 63.5 410.5 9.5 469.9 1.6 16
Figure 3 16" Diameter Flange

4
Facility Layout

The manufacturing facility has grown and expanded as demand for specific products
has increased. This led to equipment being purchased and located where there was
space, which Lee thinks may or may not be in the best location from a process
efficiency point of view. The current layout can be seen in Figure 4.

Figure 4 Shop Floor Layout.

5
Product route

Lee has spent several weeks collecting data and has been able to identify four
different routes through the factory. The first of which is shown in Figure 5 with the
remainder given in the appendix.
The generic process route consists of Sawing the bar to length (if manufactured form
bar and not from a semi-finished forging), turning, drilling, inspecting, marking and
packing.

PRODUCT RO

Figure 5 Production Route 1

6
An alternative representation of the process route can be seen in Figure 6.

Figure 6 Manufacturing Process and Product Route.

7
Current Value Stream Map

From compiling the above data and direct observation Lee has created the following Value Stream Map, Figure 7.

8
Figure 1 Current Value Stream Map
Appendix

9
 PRODUCT ROUTE

Figure 8 Product Route 1

10
Figure 9 Product Route 2

11
 Figure 11
Product
Route 4

Figure 2 Product Route 3 12

 Current Raw Material Inventory and WIP for Reference to Make Batch Size Assumptions

Bar For CNC-T1,T3,T4 For CNC-D2, D3, D4 For Inspect For Mark For Pack
79 parts, 1 to 7 types of
2 weeks stock Route 1 137 parts, 1 to 10 types of parts parts 20 0 45
Forge For M-L1, L2          
4 months stock 64 parts, 1 to 10 types of parts            
For Mazak INT 200 For Mazak VAX 500 5 10 10
77 parts, 1 to 5 types of
Route 2 40 parts, 1 to 5 types of parts parts
For Mazak INT 300    
17 parts, 1 to 3 types of parts      
For CNC-T2, M-L3, L4 For CNC-D5 4 0 4
Route 3 6 parts, 1 to 2 types of
16 parts, 1 to 5 types of parts parts
For CNC-T&D5   6 0 0
Route 4
6 parts, 1 to 4 types of parts  

Note: This inventory and WIP is just for reference so that you have an rough idea when you make assumption on batch size.
The WIP of parts number for different operation and types number varies day by day. They are average figures based on my one week statistics.

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Current Value Stream Map

Figure 12 Some Ideas for Improving the Site

14
Flange Production: Saw Cutting Process Data
304, 316 Material Bar Saw Cutting Data
Bar Size (Ømm) Saw Type Used for Cutting Cutting Time (mins) Varation
3
76 ±1
82  
88  
95  
101 5 ±1
107  
114  
120 HA250  
127  
133  
139  
152 10 ±2
165  
177  
185  
190  
200 17 ±3
203  
215  
220  
228 HA400  
241  
254 25 ±4
279  
285  
304 38 ±4
340  
355 59 ±5
381 HA500  
406 75 ±6
431  
457 100 ±7
520 HA700 150 ±8
580  
640   220 ±10

Duplex Steel e.g. F44 and Nickel Alloy e.g. 625 Material Bar Saw Cutting Data
4
76   ±1
82  
88  
95  
101 10 ±2
107  
114  
120 HA250  
127  
133  
139  
152 22 ±3
165  
177  
185  

15
190  
200   37 ±4

Administrative Process

Physical equipment in process

4 x PC for orders (4 staff)

1 printer - job sheets (carbon paper)
1 printer - WRI cards, drawings, test
certificates (normal)
1 PC - Diana/Peter -digital filing,
printing
(Peter also has PC but not necessarily
required for this particular process)

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