Process Mapping and Production Optimization

Overview

Wendell August Forge produces customizable metalware for a wide range of customers. Everything is handmade by skilled craftsmen at their forge in Mercer, PA. Wendell August Forge offers a variety of products that can be grouped into high volume annual products, medium volume products, and low volume custom products. Three products representing each group are ornaments, circular coasters, and trays respectively.
Wendell August Forge currently has inefficiencies in three important processing areas: metal preparation, ribboning ornaments, and packaging. The problem with metal preparation and ribboning ornaments is that it is all done by hand, which is time consuming. Packaging is also completed by hand but is done in two separate areas of the factory, adding a travel time in delivering materials and finished products.
This project aimed to identify common bottlenecks found in Wendell August Forge’s production through the creation of process maps and investigating ways to optimize them. The primary objective of this project was to develop process efficiency maps for ornaments, circular coasters, and trays. The secondary objective of the project is to investigate means to improve the process efficiency of metal preparation, ribboning, and packaging areas. Improving such sites helped to reduce time spent on nonvalue-added activities and lead time.
Time studies were performed on the three areas of interest to break down each process into its essential elements, analyze them, and obtain each standard time. Then, the team developed process maps for the three areas of focus: metal preparation, ribboning, and packaging. After the original time studies and process maps were completed, the team made changes to the process to test for improvements. It was found that by using a machine stencil to outline, the average stencil time was reduced to one second from six seconds. Further, having a packaging assembly line and more full-time employees will reduce the wait times associated with waiting for part-time employees.
Overall, to address the problems identified by Wendell August Forge in the metal preparation area, ribboning area, and packaging areas the following changes are recommended. In the metal preparation area, using the outlines used to cut out the final product as a stamp to press an outline into the metal sheet would improve this area and save time. In the ribboning area, a ribbon threading tool would save time and improve ergonomics. The packaging area could benefit from additional employees. Further, to improve the efficiency of the packaging process it is recommended to switch to an assembly line process. This is more feasible with more packaging staff.
After testing for improvements and completing improved process maps for the trays, ornaments, and coaters the following time improvements were found. The total time for the tray process decreased from 53 minutes and 57 seconds to 53 minutes and 29 seconds. The total time for the ornament process decreased from 53 minutes and 7 seconds to 52 minutes and 59 seconds. The total time for the coaster process decreased from 53 minutes to 52 minutes and 55 seconds.

Objectives

This project aimed to identify common bottlenecks found in Wendell August Forge’s production through the creation of process maps and to investigate ways to optimize them.
The primary objective of this project was to develop process efficiency maps for ornaments, circular coasters, and trays. The secondary objective of the project is to investigate means to improve the process efficiency of metal preparation, ribboning, and packaging areas. These areas are tedious and time-consuming, making them bottleneck stations in the production line. Improving such sites helped to reduce time spent on nonvalue-added tasks and lead time.

Approach

Task 1 was to develop process maps for the ornaments. Amanda Brundage and Saleen Khraishi conducted a time study on the metal preparation workstation to determine the standard time and further the process map.

Task 2 was to develop a process map for the coasters, which Sebastian and Steven accomplished by conducting a time study on the workstation.

Task 3 was to develop a process map for tray production, which Yamiya Fowlkes accomplished by conducting a time study on the workstation.
The process maps helped improve efficiency, provided details about the processes, helped develop improvement ideas, and improved process documentation. The process maps helped identify bottlenecks and delays and set process metrics. The team accomplished the three tasks simultaneously.

Task 4 was to analyze the time studies and conduct research on how to optimize the three products and the three areas of focus.

For Task 4.1 the time studies provided us with an understanding of the steps in the metal preparation process along with the specifications of the metal plates used on the production line for the trays. Standardizing the dimensions of the metal plates would reduce the time spent on the process.

For Task 4.2 the time studies helped us determine the standard time it took an employee to place a ribbon in an ornament. With this information, research was conducted to see if it was convenient to automate the ribboning process since ornaments are a high-volume product.

For Task 4.3 the time studies helped us determine the number of workstations that were necessary to improve the flow of packaging. Also, the studies were used to decide the amount of personnel needed for the area. A cost analysis was conducted to determine the total cost of the suggested improvements. Steven accomplished the task.

Task 5 was completing project deliverables. This includes a final report, a presentation, a poster, a project summary, and a YouTube video detailing the project. The final report contains recommendations for improving lead time by optimizing the three areas. It would also include process maps for the three products at different levels of manufacturing. The team will be delivering a presentation in the Bryce Jordan center. The team held several meetings to accomplish task 5.

Outcomes

To improve the stenciling process, an operator could use the machine that cuts out the finished product to lightly apply the outline of the stencil into the metal sheet.

Seven full-time employees are needed to work in the packaging line to improve packaging. The packaging line process would work by having three packaging employees at each counter performing the same task, so one person is doing only part of the process.

As for the ribboning area, Wendell August Forge would benefit from ribbon threading tools that save time and improve ergonomics.