Headlamps Assembly Loop for Ford Aero Headlights

Valverde-Ventura ReneVouravis Veerakachen

Current Situation

• 7.2 hours of production shifts• The current production of 2892 pieces per

shifts can’t meet the required production of 3002 pieces per shifts

• Need changes in designs to improve the performance of the loop

Current Layout

Requirement

• 3002 pieces of good parts during 7.2 hour shifts.

• Minimum cost

Design Changes

• Number of pallets• Operating procedure for Leak Test Stations• Additional Aimer

Number of Pallets

• Find the Optimum number of Pallets

• Minimum number of pallet is 44

• The Optimum number of pallet is 52

• Delivers the production of 2902 parts per shift

Average 90% Lower C.I. 90% Higher C.I.44 2892.75 2888.03 2897.4746 2897.50 2892.61 2902.3948 2899.67 2895.39 2903.9450 2895.92 2888.26 2903.5852 2902.17 2896.73 2907.6154 2895.25 2891.53 2898.9756 2897.67 2890.21 2905.12

Number of PalletsProduction in 7.2 Hour Shift

Production

2875

2880

2885

2890

2895

2900

2905

2910

44 46 48 50 52 54 56

Number of Pallets

Par

ts

Production in 7.2 Hour ShiftAverage

Production in 7.2 Hour Shift90% Lower C.I.

Production in 7.2 Hour Shift90% Higher C.I.

Change Operating Procedure of Leak Test Station

• Originally, 3 machines in the station operate simultaneously

• We modified the operating procedure that each machine in the stations works independently

Average 90% Lower C.I. 90% Higher C.I.Before 2902.17 2896.73 2907.61After 3192.75 3187.25 3198.25

Change Operating Procedure

Production in 7.2 Hour Shift

Additional Aimer

• Reduce the Blocking rate of previous station

• Improve the loop performance

Average 90% Lower C.I. 90% Higher C.I.Before 3192.75 3187.25 3198.25After 3225.83 3220.46 3231.2

Put One More AimerProduction in 7.2 Hour Shift

Recommendation

• Changing operating procedure of the Leak Test Stations should be done first

• Next, change the number of pallets to the optimum

• Add the Aimer, depending on the management’s cost justification

Modified Layout

The End