Impact of Part Proliferation on a High Mix Low Volume Manufacturing Environment

Impact of Part Proliferation on a High Mix Low Volume Manufacturing Environment
Author: Paige Denise Youngerman
Publisher:
Total Pages: 41
Release: 2020
Genre:
ISBN:

This project set out to create a framework for conducting a cost benefit analysis of part proliferation looking into first, second and third order effects of part specialization within the entire Caterpillar enterprise. This project builds on previous internal efforts to reduce complexity by evaluating the impact of increasing part count on design, procurement, inventory, production and both internal and external quality. Part proliferation occurs as parts are designed or redesigned to increase safety, comply with changing regulatory rules, improve profitability, serve niche customer demands and increase percentage of industry sales (PINS). The main driver for creating unique parts instead of common components comes from the incentivization to optimize designs for individual models and applications with a relatively narrow perspective on the cost function underlying parts proliferation. Caterpillar factories assemble final products from unique components sourced from both internal and external suppliers. Part proliferation increases inventory and requires design and upkeep actions to create and produce the new product. Many of the challenges associated with proliferation are hidden or poorly understood as they involve factory and quality efficiencies which tend to be aggregated at a high level or dealt with as a one-time issue. Other benefits such as inventory reduction are clearer but were analyzed by this project to understand the total impact of a unique part to the system. This project focused on decreasing the proliferation of axle options within the Medium Wheel Loader (MWL) and Large Wheel Loader (LWL) product families, with the outcome of creating a generalized framework for use throughout the enterprise on any product family. The study found that the impact of including the areas of operational inefficiencies, internal quality, and external quality, when adding an axle configuration increased the costing analysis by 64%. The details of this analysis are presented in the following dissertation.

High-mix Low-volume Manufacturing

High-mix Low-volume Manufacturing
Author: R. Michael Mahoney
Publisher: Prentice Hall
Total Pages: 246
Release: 1997
Genre: Business & Economics
ISBN:

Many of the problems manufacturers face seem to defy intuitive solutions . . . and are full of uncertainty and risk. But every situation--no matter how tentative or unsettling it seems--can be logically analyzed and systematically mapped out. "High-Mix, Low-Volume Manufacturing" covers the entire spectrum of manufacturing-related topics, from competitive strategies through performance measurements. Although there is a special focus on high-mix, low-volume manufacturing, there is much useful and valuable information for people in all other types of manufacturing. This book is a thorough reference for practitioners and academics interested in how manufacturing should and can be run. "High-Mix, Low-Volume Manufacturing" is a groundbreaking work, integrating ideas from many sources. In this book, manufacturing fundamentals are re-examined in a way that often gets overlooked by corporate strategists. This book is a comprehensive, practical, and detailed educational reference covering "global" concepts through "tactical" ideas in a clear and concise manner. The goal of this book is to develop the manufacturing core competencies required to obtain a competitive advantage. This book has both an immediate and long-term payoff.

Design for Manufacturability

Design for Manufacturability
Author: David M. Anderson
Publisher: CRC Press
Total Pages: 472
Release: 2014-02-04
Genre: Business & Economics
ISBN: 1482204940

Design for Manufacturability: How to Use Concurrent Engineering to Rapidly Develop Low-Cost, High-Quality Products for Lean Production shows how to use concurrent engineering teams to design products for all aspects of manufacturing with the lowest cost, the highest quality, and the quickest time to stable production. Extending the concepts of desi

The Practitioner's Guide to POLCA

The Practitioner's Guide to POLCA
Author: Rajan Suri
Publisher: CRC Press
Total Pages: 436
Release: 2018-04-09
Genre: Business & Economics
ISBN: 1351170759

POLCA (Paired-cell Overlapping Loops of Cards with Authorization) is a card-based visual control system that manages the flow of jobs through the shop floor: at each operation, it controls which job should be worked on next to meet delivery targets. POLCA ensures that upstream operations use their capacity effectively by working on jobs that are needed downstream, while at the same time preventing excessive work-in-process (WIP) build-ups when bottlenecks appear unexpectedly. POLCA is particularly suited to companies manufacturing high-mix, low-volume and customized products. Such companies struggle with long lead times, late deliveries, and daily expediting to meet delivery dates. ERP systems are not designed to deal with this highly variable environment, and add-on software such as Finite Capacity Scheduling systems can require complex installation. Also, the Kanban system does not work well with low-volume or custom production. POLCA has delivered impressive results in such environments. It does not require any complex software implementation: it can be used without an ERP system or it can seamlessly complement an existing ERP system. This book: Provides a step-by-step roadmap on how to implement POLCA; invaluable for both companies that wish to implement POLCA as well as consultants and academics advising such companies. Explains the concepts in practical and easy-to-understand terms by showing detailed shop-floor examples. Includes more than 100 illustrations for understanding how POLCA works as well as for elaborating on details of the implementation steps. Contains case studies written by company owners and executives documenting their POLCA implementation process and the results achieved in various industries in six countries.

Creating Mixed Model Value Streams

Creating Mixed Model Value Streams
Author: Kevin J. Duggan
Publisher: CRC Press
Total Pages: 258
Release: 2018-02-05
Genre: Business & Economics
ISBN: 1439868441

Following in the footsteps of its bestselling predecessor, Kevin J. Duggan, an executive mentor and recognized authority on Lean and Operational Excellence, draws on more than 10 years of experience and learning to provide Creating Mixed Model Value Streams, Second Edition. This second edition takes a step-by-step approach to implementing Lean in c

Life-Cycle of Engineering Systems: Emphasis on Sustainable Civil Infrastructure

Life-Cycle of Engineering Systems: Emphasis on Sustainable Civil Infrastructure
Author: Jaap Bakker
Publisher: CRC Press
Total Pages: 438
Release: 2016-11-18
Genre: Technology & Engineering
ISBN: 1498777015

This volume contains the papers presented at IALCCE2016, the fifth International Symposium on Life-Cycle Civil Engineering (IALCCE2016), to be held in Delft, The Netherlands, October 16-19, 2016. It consists of a book of extended abstracts and a DVD with full papers including the Fazlur R. Khan lecture, keynote lectures, and technical papers from all over the world. All major aspects of life-cycle engineering are addressed, with special focus on structural damage processes, life-cycle design, inspection, monitoring, assessment, maintenance and rehabilitation, life-cycle cost of structures and infrastructures, life-cycle performance of special structures, and life-cycle oriented computational tools. The aim of the editors is to provide a valuable source for anyone interested in life-cycle of civil infrastructure systems, including students, researchers and practitioners from all areas of engineering and industry.

Orthobiologics, An Issue of Physical Medicine and Rehabilitation Clinics of North America, E-Book

Orthobiologics, An Issue of Physical Medicine and Rehabilitation Clinics of North America, E-Book
Author: Michael Khadavi
Publisher: Elsevier Health Sciences
Total Pages: 329
Release: 2022-11-22
Genre: Medical
ISBN: 0323919901

In this issue of Physical Medicine and Rehabilitation Clinics, guest editors Drs. Michael Khadavi and Luga Podesta bring their considerable expertise to the topic of Orthobiologics. Use and research surrounding naturally derived substances that are used to help heal and repair orthopedic injuries are expanding rapidly. In this issue, top experts discuss the most up-to-date uses of orthobiologics in the rehabilitation setting. Contains 16 practice-oriented topics including orthobiologics for spine disorders; evidence and techniques in prolotherapy; orthobiologic interventions for muscle injuries; special populations in orthobiologics: athletic, elderly, and pediatrics populations; rehabilitation protocols for orthobiologic procedures; orthobiologic techniques for surgical augmentation; and more. Provides in-depth clinical reviews on orthobiologics, offering actionable insights for clinical practice. Presents the latest information on this timely, focused topic under the leadership of experienced editors in the field. Authors synthesize and distill the latest research and practice guidelines to create clinically significant, topic-based reviews.