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TEAMSKILL an exploration of manufacturing

TEAMSKILL an exploration of manufacturing. The development of this simulation was sponsored by Honeywell and Metal Working Production magazine and run twice as a National Production Management Contest in the UK. Introduction. You manage the operation of a factory. Planning the Factory

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TEAMSKILL an exploration of manufacturing

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  1. TEAMSKILLan exploration of manufacturing The development of this simulation was sponsored by Honeywell and Metal Working Production magazine and run twice as a National Production Management Contest in the UK.

  2. Introduction You manage the operation of a factory. • Planning the Factory • Scheduling Materials and Production • Inventory Management • Production Control • Ensuring Timely and Efficient Operation

  3. Process You will be divided into small teams each of which must: • Analyse the situation • Plan the Factory • Run the Factory for several Months • Combine with the other teams to discuss and compare results and strategies

  4. The Situation • The factory that you are to manage makes small electric motors • The factory is about to move to a new site and this gives you the opportunity to replace machinery, change layouts, etc. • And this move means that you are replacing the existing, senior manufacturing management.

  5. The Roles Although you are free to organise your team in any way you wish, your responsibilities are likely to include: • Works Manager (team leader) • Production Manager • Inventory Control Manager • Manufacturing Cost Accountant • Industrial Engineering Manager

  6. The Product TheElectric Motor consists of these main parts: • Stator • Rotor • Frame And there are five models: • 240/220 Volt – long frame • 240/220 Volt – short frame • 117 Volt – long frame • 117 Volt – short frame • 240/117 Volt – long frame

  7. The Production Units You will manage in detail these manufacturing units: • Punch Press (turns steel strip into punchings) • Rotor Assembly (uses punchings & aluminium) • Stator Assembly (uses punchings & wire) • Final Assembly (uses stators, rotors & frames)

  8. The Materials You will manage in detail these materials: • Steel Strip (magnetic motor elements) • Aluminium (electrical rotor elements) • Copper Wire (electrical stator elements) • Casting Sets (motor frame)

  9. SS Production Process PP CW RP A SP SA RA F S R Raw Materials FA In Process Materials Finished Products FM

  10. Decisions • decide a team name (up to six letters) • for the first period make planning decisions • for all periods schedule the factory

  11. Factory Planning Decisions • Punch Press Machine • Die Cast Layout • Number of Stator Lines • Stator Staffing • Casting Set Supplier • Optional Reports • Storage Area Sizes

  12. Factory Scheduling Decisions • Material Purchases • Minimum Production Rates • Maintenance Frequency • Machine Set-Ups • Final Assembly Schedule • Days Shutdown

  13. Results • Decisions • Manufacturing Account • Capital Statement • Production Summary • Customer Research • Inventories (at month end) • Optional Reports • Comments • Current Set-Ups (end of month)

  14. Observations • it takes time to understand • but the factory still must be run • so your decisions will not be perfect • time will be a constraint • but, by the end you should be just in command of your business! • your business competencies will be challenged • make sure you use the talents of your fellow team members • ensure that you allow time to reflect

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