Kautex Textron

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Kautex Textron

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Introduction: (in text citation needed) -current problem with line 5 1-Low rate of OEE, caused by the cycle time being high for each station, with an average of 128 seconds per station. 2-The average OEE is %62. 3-The ideal cycle time is 79-80 seconds per station. 4-The average OEE needs to be improved from %62 to %80, and that cannot be done unless the cycle time was reduced to approximately 90-100 seconds per station. -What is OEE and how to calculate it. 1-breif definition about OEE. 2-OEE= Quality * (actual cycle time/ ideal cycle time) * available time -Why this problem happened. 1-lack of training. 2-varaiaty of components. 3-the material handler wastes time by commuting between stations to deliver materials from one station to the other. 4-the stations layout lack space between stations which affects the workflow. -Brief summary of the process for making a fuel tank (Hybrid and Saddle). 1-first the fuel tank is formed in the BMM (Blow Mold Machine)*. (https://patents.justia.com/patent/10408382 ) 2-and then it goes to the welder*. (File attached) *process 1 and 2 use automation cells 3-Then it goes to the assembly line (torque, helium and heat shield stations) ** A-after the fuel tank is formed, it goes to the toque station. (File attached). B-then it goes to the helium station. (File attached) C-Finally it goes to the heat shield station. (File attached) **process 3 uses buffers to move fuel tanks from one station to the other. -Briefly describe how to solve the problem. 1- Identifying the root of the problem. 2- Use lean manufacturing (time study method) for workflow. (The time study will be attached if needed) 3- Use Kaizen method a- What is Kaizen method (The Toyota way) b- How to use it in this current problem End of introduction Background: (in text citation needed) – -What is a saddle (conventional) fuel tank, and what is a hybrid fuel tank. (File attached, include the pictures, they will be attached) * Conventional Technology ( https://www.kautex.de/en/automotive/conventional-fuel-systems ) -What is the deference between hybrid fuel tank and saddle fuel tank, and what is the process for each. (File attached) -Talk about what is the ideal cycle time: Constants: Quality = %99 Ideal cycle time = 79 seconds per station for the assembly line (torque station, helium station, heat shield station) Available time = %100 Another way to calculate OEE Production target = 360 fuel tank per shift OEE = (Actual production/Production target)*100 For example: OEE = (223/360)*100 = %62 End of Background Design methodology: (in text citation needed) -write in depth about each station*: A- BMM (Blow Mold Machine), uses automation cells to handle material B- Welding station uses automation cells to handle material C- Torque station, uses buffers and 1 worker to handle material. D- Helium station, uses buffers and 1 worker to handle material. E- Heat shield station, uses buffers and 1 worker to handle material. *information about all stations are attached in the file.

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