IMEG was hired by a startup drone manufacturer to develop processes and layout concepts for a new product. This customer was launching their first product at a new facility with an area of 73,000 ft2.
THE PROBLEM
new process & plant layout development
Lacking documentation for assembly of processes
Unknown process time, process balance, and manning
Unknown assembly line / station configuration
Needed recommendations for improving assembly efficiently
THE PLAN
Observe and document all assembly processes
Develop MODAPTS to estimate process time
Calculate takt time based off of production requirements
Calculate manning from process and takt time
Balance processed based on manning and process constraints
Develop layout concepts for assembly area
Develop improvement recommendations from process observations
THE RESULTS
Delivered documentation for the entire assembly process of 20 subassemblies
Delivered process time and manning estimates for the entire assembly process
Balanced all assembly processes across 33 stations
Developed optimal process flow to feed subassemblies from individual workstations to an assembly line
Developed 6 different layout concepts to plan for the arrangement of 24 separate workstations and a 9 - station assembly line
Developed several improvement recommendations that would reduce the total process time by 11.88%
