7ENT1128 Lean Manufacturing & Services Assignment Sample

Introduction

The X bicycle company, which goes by the appellation of X, employs more than 100 people in its many capacities. Like the other businesses, Company x was owned and operated by family members who were staunch supporters of traditional business practises, as was the case with the other firms.

Case scenario

 The vast majority of the components used in the company’s classic single- and multi-speed bicycles are supplied by X, a bicycle component manufacturer situated in the Charlotte, North Carolina, region and based in the United States of America. X is a bicycle component manufacturer located in Charlotte, North Carolina, that specialises in high-end bicycle components. At a later stage, the separate components are welded together and assembled to produce the completed product at the company’s production plant in Charlotte, North Carolina. Firm X, a bicycle distribution business, generates $44 million in yearly revenue, while also manufacturing more than 220,000 bicycles in the course of its operations. Firm X is a bicycle distributor that serves a diverse variety of customers (Nallusamy,2018).

process for redesigning Company X assembly line and production warehouse layout to minimize waste

Production at distribution centres is similar to that of other warehouses and distribution centres, with activities such as product unloading, quality assurance testing (QA), and shelf organisation taking place constantly throughout the day and evening. In order for the warehouse to work successfully, orders from customers have accumulated in the warehouse and must be picked, packed, and delivered to their appropriate destinations all at the same time for the warehouse to function properly (Berg, 1999). Providing customers with a range of alternatives rather than just one, providing interim storage for items that will be destroyed or recycled, and acting as a buffer for transshipments are all objectives. An efficient sorting centre, which allows for the efficient sorting of raw materials, components, and finished goods, is critical to the logistical success of any manufacturing facility. Every manufacturing facility, regardless of its size, has a sorting centre that is well-organized and important to the success of the company’s logistical operation (Koster et al., 2007).

Identify and discuss the critical factors that influence the redesigning process.

Regarding accessibility, the availability of warehouse systems that are both conveniently accessible and have an adequate quantity of storage space should be a key priority for the industry in terms of accessibility, according to the report (Lihui and Hsieh, 2006). It is necessary to increase warehouse efficiency in order to reduce inventory levels to the absolute minimum while yet preserving maximum operational flexibility. … In order to reach this goal and maintain a high level of warehouse management performance during the course of the operation, it is necessary to take into account a large number of critical aspects. When evaluating a firm, one factor to examine is its ability to ship orders on time and with accuracy. In addition, the turnover rate of its personnel, the dollar/unit capacity of its inventory, and the turnover rate of its staff are all important factors to consider. The following is the conclusion that Cantini reached as a result of his investigation: (2021). Because we need to fulfil our deadlines, we expect that the components we have requested from suppliers will be delivered to us as soon as possible, and that they will arrive on time and in excellent shape, as we have previously said (Qattawi, 2019). If the order is not received at the warehouse in a right and full state, it is conceivable that it may be compromised between the time it is received in the warehouse and the time it is delivered, resulting in the loss of valuable time for both warehouse staff and consumers.

 how you would implement lean tools and techniques to optimize Company X supply chain processes.

The fact that it has the potential to have a direct impact on the way a warehouse operates makes it one of the most important considerations to make when planning a storage facility. Reduce the size of the warehouse and use the most efficient route to pick orders in order to reduce trip time and travel distance, resulting in a reduction in the total cost of the goods and services provided by the company. Minimize the size of the warehouse and use the most efficient route to pick orders in order to reduce trip time and travel distance (Sangwa, 2022).

As a result of a well-designed warehouse, order picking will be more efficient, and as a result, the overall performance of the warehouse will be improved. Picking orders is one of the most time-consuming, labor-intensive, and financially draining chores that can be found in almost any warehouse and distribution centre (Braccini, et al., 2018).

Challenges

Even if order picking is done manually, the warehouse’s design may have an impact on how effectively a warehouse is organised in terms of order picking, regardless of whether the picking is automated or done manually. In order to make an educated choice, it is vital to weigh the benefits and downsides of each alternative strategy (Cantini, 2021). A number of important aspects in order picking include the amount of items selected as well as the layout design and order combination. Other important considerations include the picking route, trip time, and distance traversed, all of which are affected by the warehouse layout. In addition, the route chosen, the length of the journey, and the distance travelled are all important factors to consider. In certain cases, depending on how effective these efforts are, they may have a direct influence on the overall efficiency of the warehouse, as well as the total amount of money that is spent in it (Chang, 2020).

Conclusion

As a result of overstocking, the inventory grows in size, resulting in a net financial loss as a result of the practise.

It is possible to save money on a number of expenditures by investing in a professionally created warehouse, including warehouse space, utilities and maintenance, damage and theft, insurance, and taxes, among other things, by investing in a professionally built warehouse

References

Braccini, A.M. and Margherita, E.G., 2018. Exploring organizational sustainability of industry 4.0 under the triple bottom line: The case of a manufacturing company. Sustainability, 11(1), p.36.

Cantini, A., Carlo, F.D. and Tucci, M., 2021. Serious game for lean layout planning: a proposal for involving company staff within the design process. International Journal of Product Development, 25(1), pp.62-84.

Chang, K., Tan, G., Wang, X., Zhou, C. and Wei, L., 2020, April. Lean improvement of product P assembly line based on value stream map. In IOP Conference Series: Materials Science and Engineering (Vol. 825, No. 1, p. 012007). IOP Publishing.

Nallusamy, S. and Saravanan, V., 2018. Optimization of process flow in an assembly line of manufacturing unit through lean tools execution. In International Journal of Engineering Research in Africa (Vol. 38, pp. 133-143). Trans Tech Publications Ltd.

Qattawi, A. and Chalil Madathil, S., 2019. Assembly line design using a hybrid approach of lean manufacturing and balancing models. Production & Manufacturing Research, 7(1), pp.125-142.

Sangwa, N.R. and Sangwan, K.S., 2022. Leanness assessment of a complex assembly line using integrated value stream mapping: a case study. The TQM Journal, (ahead-of-print).

………………………………………………………………………………………………………………………..

Know more about UniqueSubmission’s other writing services:

Assignment Writing Help

Essay Writing Help

Dissertation Writing Help

Case Studies Writing Help

MYOB Perdisco Assignment Help

Presentation Assignment Help

Proofreading & Editing Help