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Sonic Speakers Facility Design

Sonic Speakers Facility Design. Chris Chesla Dan Hovde Tony Niemczyk Mike Rosenthal. Outline. Introduction Approach and Methodology Results Recommendations Conclusion. Introduction. Sonic Speakers purchased new Facility Engineering team New layout New design of production

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Sonic Speakers Facility Design

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  1. Sonic Speakers Facility Design Chris Chesla Dan Hovde Tony Niemczyk Mike Rosenthal

  2. Outline • Introduction • Approach and Methodology • Results • Recommendations • Conclusion

  3. Introduction • Sonic Speakers purchased new Facility • Engineering team • New layout • New design of production • Plan growth for next five years

  4. Approach and Methodology • Current Situation • Lean Manufacturing • Line Balancing • Inventory Control • Layout • Truck Routing

  5. Current Situation • 120,000 square feet • 16 docks • Work 10 hr days 5 days a week

  6. Lean Manufacturing • Used in plant layout • Minimize distances traveled • Balance lines • Assembly lines • Based on pull system • Cross-trained workers • Inventory • Reduce 20%

  7. Line Balancing • Cellular Design • Cross-trained teams • In charge of Quality • Lines • Based on speaker size • Designed to peak demands • Run north to south • Puts finished products close to dock

  8. Inventory Control • ABC inventory Control • Most often used • Easiest to access • Least used • Hardest to access • Rank • A ~ Highest Volume Flow • B ~ Medium Volume Flow • C ~ Lowest Volume Flow

  9. Plant Layout • Warehouse • 27,500 square feet including aisle • 12 foot aisles • Stack three pallets high • Wood and Carpet stored separate • Located near production • Assembly located in center • Easy access to all areas

  10. Truck Routing • 15 routes • 6 to 7 orders per truck • Shipped 3 times a week • Filled in reverse order

  11. Results • Tact times • Yellow ~ 24 min • Blue ~ 28.09 min • Green ~ 28.09 min • Red ~ 73.34 min • Line efficiencies

  12. Results Cont. • Reduction of Inventory

  13. Recommendations • Short-term • Purchase necessary items • Classify inventory • Arrange inventory • Develop truck routes • Manage Flow • Long term • Diminish Inventory • Improve line efficiency • Multifunctional work staff

  14. Conclusion • Cellular manufacturing • Engineered plant layout • Lean Manufacturing • Decline inventory • Reduce travel • Inside the plant • Outside the plant

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