UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Lead Time Improvement by Re - Layout at
Aerospace Company
Thesis submitted in accordance with the requirements of the University Technical of Malaysia Malacca for the Bachelor Degree of Manufacturing
Engineering in Manufacturing Process
By
Khairul Anwar B. Haron
(B050410068)
LEAD TIME IMPROVEMENT BY RE - LAYOUT AT
AEROSPACE COMPANY
(CTRM AERO COMPOSITE SDN BHD)
KHAIRUL ANWAR BIN HARON
DECLARATION
I hereby, declared this thesis entitled “Uncertainty Measuring and Evaluating the Measurement of Gauge Block by Universal Measuring Machine” is the results of my own research except as cited in references.
Signature : ……….
Author’s Name : Abu Musa Asha’ari bin Mohd Sarif
Date : ………
UTeM Library (Pind.1/2007)
UNIVERSITI TEKNIKAL MALAYSIA
MELAKA
BORANG PENGESAHAN STATUS TESIS*
JUDUL: LEAD TIME IMPROVEMENT BY RE-LAYOUT AT AEROSPACE COMPANY (CTRM Aero Composite Sdn Bhd)
SESI PENGAJIAN: 2007/2008
Saya KHAIRUL ANWAR BIN HARON mengaku membenarkan tesis ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka .
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja.
3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan (√)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
(TANDATANGAN PENULIS)
Alamat Tetap:
NO 59 JALAN BUKIT SETONGKOL 8 TAMAN SRI SETONGKOL 8
25200 KUANTAN, PAHANG D.M
Tarikh: 12 MEI 2008
Disahkan oleh:
(TANDATANGAN PENYELIA)
Cop Rasmi:
APPROVAL
This PSM submitted to the senate of UTeM and has been as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Process). The members of the supervisory committee are as follow:
……… Main Supervisor (Dr. Mohd Rizal bin Salleh)
DECLARATION
I hereby, declare this thesis entitled “Lead Time Improvement by Re-Layout at
Aerospace Industry” is the result of my own research
except as cited in the references.
Signature : ……….
Author’s Name: KHAIRUL ANWAR B. HARON
ABSTRACT
ABSTRAK
DEDICATION
For my beloved family :
HARON B HJ IDRIS
NORHAYATI BINTI SAARI
RIZAL BIN HARON
LENIE MASTURA BINTI HARON
MUHAMAD AZRI BIN HARON
For my adored friends:
ACKNOWLEDGEMENTS
Alhamdulillah and Thank to Allah S.W.T. with all His Gracious and His Merciful for giving me strength and ability to accomplish this project research successfully. I would like to take the utmost opportunity to express my sincere and gratitude to my supervisor, Dr. Mohd Rizal Bin Salleh who is always giving me supports and guidance throughout the year in completing this Final Year Project 1 & 2 until up to this stage in victory.
Also with the greatest thanks to my beloved parents and family who always pray and give the encouragement while pursuing my research and project. Their sacrifices are never being forgotten.
Besides, thanks a lot to Prof. Dr. Mohd Razali Bin Muhamad, Dean of Manufacturing Engineering, Malaysia Technical University of Malacca, Pn Hjh Rohana Binti Abudllah and also Mr. Nik Mohd Farid Bin Che Zainal Abidin as well as to all lecturers of Faculty of Manufacturing Engineering.
I also would like to convey my biggest appreciation to all the staff in CTRM Aero Composite Sdn Bhd for supporting me in accomplishes my Final Year Project without hesitation. All knowledge and experience I gained would not be forgotten.
TABLE OF CONTENTS
Abstract………..………...….i
Dedication………...……….iii
Acknowledgement………..……….iv
Table of Contents ………..……...v
List of Figures ………...………...xii
List of Tables ……….………...xvi
List of Abbreviations, Symbol and Specialized Nomenclature………...xviii
List of Appendices ……….…………...xix
1. INTRODUCTION 1
1.1. Introduction 1
1.2. Project Background 2
1.3. Problem Statement 3
1.4. Aims and Objective 3
1.5. Scope of Project 4
1.6. Expected Result 4
1.7. Methodology and Flow Chart 5
1.8. Summary 5
2. LITERATURE REVIEW 7
2.1 Introduction of plant layout 7
2.2 The Plant Layout Problem 9
2.2.1 Minor changes in present layouts 10
2.2.2 Existing layout rearrangement 10
2.2.3 Relocating into existing facilities 10
2.2.4 Building a new plant 11
2.3 Objective of layout planning 11
2.4 Traditional Types of Facility Layout 11
2.5.1 Agile Manufacturing Layouts 13
2.5.2 Flexible Plant Layouts 14
2.5.3 Fractal Layout 15
2.5.4 Holonic layout 16
2.5.5 Hybrid Cellular Layouts 16
2.5.6 Modular Layouts 17
2.5.7 Multi-Channel Manufacturing 17
2.5.8 Organization of Factories as Responsibility Networks 18 2.6 Trends in Facility Layouts observed in Industry 19 2.6.1 Reconfigurable Manufacturing Systems (RMS) 19
2.6.2 Flow Manufacturing – Linked Cells 20
2.7 Systematic Layout Planning With Production Flow Analysis 21
2.8 Tools for design of facility layouts 25
2.9 Company Overview (CTRM Aero Composite Sdn Bhd) 30
2.9.1 Introduction 30
2.9.2 Process Flow: A320 Phase 1- Leading Edge (LE), Tailing Edge (TE), Aileron, Over Wing, Under Wing, A320/A321
Affixed Fairing, Movable Fairing 32
2.9.3 Process Flow: A320 ASSY Top Skin @ False Work 33
2.9.4 Process Flow: A320 Phase 2 Spoiler 34
2.10 Summary 35
3. METHODOLOGY 36
3.1 Introduction 36
3.2 Project Overview 37
3.3 Problem Identification 37
3.4 Data collection 39
3.5 Data Analysis 39
3.5.1 Process Analysis Technique 39
3.5.1.1 Conduct a Preliminary Study 40
3.5.1.2 Draw Up a Process Flow Chart 40
3.5.1.4 Draft an Improvement Plan 41 3.5.1.5 Data Comparison between Current Condition and
Improvement Plan Using Pareto Chart. 41
3.5.2 Workplace Analysis 43
3.5.2.1 Illuminance & Noise Measurement 43
3.5.2.1.1 Selecting the Workplace 45
3.5.2.1.2 Set Up the Equipment 45
3.5.2.1.3 Collecting Data 45
3.5.2.1.4 Analysis Data 45
3.5.2.1.5 Suggestion and Improvement Plan 45
3.5.2.2 Muscle Fatigue Assessment 46
3.5.2.2.1 Preparing the Questionnaire 46
3.5.2.2.2 Select the workplace 46
3.5.2.2.3 Analysis the questionnaire 47
3.5.2.2.4 Suggestion and Improvement Plan 47
3.6 Proposed the New Layout 49
3.7 Summary 49
4. RESULT AND ANALYSIS 50
4.1 Introduction 50
4.2 Problem Identification Using Cause-And Effect Diagram 51
4.3 Cycle time for Dry Sanding Process 52
4.4 Cycle time for Water Break Test Process 55
4.5 Cycle time for Sanding Filler Process 57
4.6 Cycle time for Filler Process 59
4.7 Cycle time for Primer Top Test Process 61
4.8 Cycle time for Primer Bottom Process 63
4.9 Cycle time for Grey/Antistatic Process 65
4.10 Cycle time for Touch Up/ Part Marking Process 67
4.11 Overall Cycle Time for Every Panel 69
4.14 Proposed area of workstation from the re-layout activity
(Improvement Plan) 75
4.15 Process Analysis Technique (Current Condition) – Process Flow 1 77 4.16 Process Analysis Technique (Current Condition) – Process Flow 2 78 4.17 Process Analysis Technique (Current Condition) – Process Flow 3 79 4.18 Process Analysis Technique (Improvement Plan) – Process Flow 1 80 4.19 Process Analysis Technique (Improvement Plan) – Process Flow 2 81 4.20 Process Analysis Technique (Improvement Plan) – Process Flow 3 82 4.21 Pareto Chart of Process Flow 1 (Time) – Current Condition 83 4.22 Pareto Chart of Process Flow 1 (Time) – Improvement Plan 84 4.23 Pareto Chart of Process Flow 1 (Distance) – Current Condition 85 4.24 Pareto Chart of Process Flow 1 (Distance) – Improvement Plan 86 4.25 Pareto Chart of Process Flow 2 (Time) – Current Condition 87 4.26 Pareto Chart of Process Flow 2 (Time) – Improvement Plan 88 4.27 Pareto Chart of Process Flow 2 (Distance) – Current Condition 89 4.28 Pareto Chart of Process Flow 2 (Distance) – Improvement Plan 90 4.29 Pareto Chart of Process Flow 3 (Time) – Current Condition 91 4.30 Pareto Chart of Process Flow 3 (Time) – Improvement Plan 92 4.31 Pareto Chart of Process Flow 3 (Distance) – Current Condition 93 4.32 Pareto Chart of Process Flow 3 (Distance) – Current Condition 94 4.33 Analysis Data: Product Process Analysis 95 4.34 Calculation of Lead Time Improvement & Operating Cost 98
4.35 Summary 101
5. DISCUSSION 102
5.1 Introduction 102
5.2 Wastes in Painting Department 105
5.2.1 Man 105
5.2.2 Management 105
5.2.3 Method 106
5.2.5 Machine 106
5.3 Defects in Painting Department 107
5.3.1 Slump at "T" stands area 107
5.3.2 Broken at chamfering 107
5.3.3 Part Marking dirty and not clear 107
5.3.4 Filler not remove in drill hole. 108
5.3.5 Scratch mark 108
5.3.6 Dented 108
5.3.7 Pin hole 109
5.3.8 Damage 109
5.3.9 Filler not remove at edge. 109
5.3.10 Paint run 110
5.3.11 Paint thin 110
5.3.12. Over spray. 110
5.4 Illuminance/Light Intensity Value 112
5.5 Analysis & Suggestion Improvement of Illuminance 114 5.5.1 Illuminance Value for Part Marking / QC Inspection Section 114 5.5.2 Illuminance Value for Sorting Section Illuminance Value 115 5.5.3 Illuminance Value for Rework Section 116 5.5.4 Illuminance Value for Filler Section 117 5.5.5 Illuminance Value for Spray Booth 1 118 5.5.6 Illuminance Value for Spray Booth 2 119 5.5.7 Illuminance Value for Spray Booth 3 120 5.5.8 Illuminance Value for Dry Sanding Section 121 5.5.9 Illuminance Value for Water Break Test Section 122 5.5.10 Illuminance Value for Masking Section 123
5.6 Noise Level Measurement 124
5.6.1 Noise Level for Part Marking / QC Inspection Section 125
5.6.2 Noise Level for Sorting Section 125
5.6.3 Noise Level for Rework Section ` 126
5.6.4 Noise Level for Filler Section 126
5.6.6 Noise Level for Dry Sanding Section 128 5.6.7 Noise Level for Water Break Test Section 129
5.6.8 Noise Level for Oven 130
5.7 Muscle Fatigue Assessment 132
5.7.1 Area of Pain Aching for Operator and Improvement Plan
(Sorting Section). 135
5.7.2 Area of Pain Aching for Operator and Improvement Plan
(Dry Sanding Section) 136
5.7.3 Area of Pain Aching for Operator and Improvement Plan
(Water Break Test Section) 137
5.7.4 Area of Pain Aching for Operator and Improvement Plan
(Filler Section) 138
5.7.5 Area of Pain Aching for Operator and Improvement Plan
(Spray Booth) 139
5.7.6 Area of Pain Aching for Operator and Improvement Plan
(Oven Section) 140
5.7.7 Area of Pain Aching for Operator and Improvement Plan
(Part Marking/ QC Inspection Section) 141
5.8 Analysis of Muscle Fatigue Assessment 143
5.8.1 Types of Treatment for Muscle Fatigue 143 5.8.2 Major of Muscle Fatigue in Painting Department 144 5.8.3 Causing of Muscle Fatigue in Painting Department 145 5.8.4 Suggestion for avoid the muscle fatigue in Painting Department 146 5.8.4.1 Risk factor: Manipulation of heavy loads 146 5.8.4.2 Risk factor: Work with high force exertion 146 5.8.4.3 Risk factor: Monotonous repetitive tasks 147 5.8.4.4 Risk factor: Long-lasting loadings 147
5.9 Summary 147
6. CONCLUSION 148
6.1 Conclusion 148
REFERENCES 150
APPENDICES
A Gantt Chart for PSM
B Traditional Types of Facility Layout [Source: Nutt, Merle (1970)] C Algorithms for Production Flow Analysis [Source: Irani (2000)] D Machine in Painting Department [Source: CTRM, 2007]
E Summarize of Thesis Reading
F Nordic Musculoskeletal Questionnaire
G Factories and Machinery (Safety, Health and Welfare) Regulation 38, 1978 (First- Aid -Box)
H Factories and Machinery (Safety, Health and Welfare) Regulation28, 1978 (Standard of Lightning)
LIST OF FIGURES
Figure 1.1 Methodology Flow Chart for PSM 6
Figure 2.1 Classification of Traditional and Non-Traditional Layouts [Source: Nutt, Merle (1970)]
13
Figure 2.2 The Systematic Layout Planning Design Process [Source: Muther, 1973]
24
Figure 2.3 Software Packages for Facility Layout [Source: Tompkins J.A. et.al (2003)]
27
Figure 24 Process Flow 1 A320 Phase 1- Leading Edge (LE), Tailing Edge (TE), Aileron, Over Wing, Under Wing A320/A321 -Affixed Fairing, Movable Fairing
32
Figure 2.5 Process Flow 2 A320 ASSY Top Skin @ False Work 33
Figure 26 Process Flow 3 A320 Phase 2 Spoiler 34
Figure 3.1 Flow Chart of Methodology 38
Figure 3.2 Process Analysis Technique Chart 42
Figure 3.3 Methodology Chart for Illuminace & Noise Measurement 44 Figure 3.4 Methodology Chart for Muscle Fatigue Assessment 48
Figure 4.1 Cause-and-effect diagram for Painting Department 52 Figure 4.2 Graph of Comparison Previous & Current Cycle Time for
Dry Sanding Process
54
Figure 4.3 Graph of Comparison Previous & Current Cycle Time for Water Break Test Process
56
Figure 4.4 Graph of Comparison Previous & Current Cycle Time for Sanding Filler Process
58
Figure 4.5 Graph of Comparison Previous & Current Cycle Time for Filler Process
Figure 4.6 Graph of Comparison Previous & Current Cycle Time for Primer Top Process
62
Figure 4.7 Graph of Comparison Previous & Current Cycle Time for Primer Bottom Process
64
Figure 4.8 Graph of Comparison Previous & Current Cycle Time for Primer Bottom Process
66
Figure 4.9 Graph of Comparison Previous & Current Cycle Time for Touch Up/ Part Marking Process
68
Figure 4.10 Chart of Overall Cycle Time for Each Panel in Painting Department
69
Figure 4.11 Paint Shop Current Layout [Source: CTRM, 2007] 73 Figure 4.12 Propose Layout of Painting Department (CTRM Aero
Composite Sdn Bhd)
74
Figure 4.13 Process Chart Worksheet for Process Flow: A320 Phase 1-Leading Edge (LE), Tailing Edge (TE), Aileron, Over Wing, Under Wing, A320/A321 Affixed Fairing, Movable Fairing (Before Improvement)
77
Figure 4.14 Figure 4.14: Process Chart Worksheet for Process Flow: A320 ASSY Top Skin @ False Work (Before
Improvement).
78
Figure 4.14 Process Chart Worksheet for Process Flow: A320 Spoiler (Before Improvement)
79
Figure 4.15 Process Chart Worksheet for Process Flow: A320 Phase 1-Leading Edge (LE), Tailing Edge (TE), Aileron, Over Wing, Under Wing, A320/A321 – Affixed Fairing, Movable Fairing (Improvement Plan)
80
Figure 4.16 Process Chart Worksheet for Process Flow: A320 ASSY Top Skin @ False Work (Improvement Plan)
81
Figure 4.17 Process Chart Worksheet for Process Flow: A320 Spoiler (Improvement Plan)
82
Figure 4.20 Pareto Charts Before Improvement (Distance) 85 Figure 4.21 Pareto Charts Improvement Plan (Distance) 86 Figure 4.22 Pareto Charts Before Improvement (Time) 87 Figure 4.23 Pareto Charts Improvement Plan (Time) 88 Figure 4.25 Pareto Charts Before Improvement (Distance) 89 Figure 4.26 Pareto Charts Improvement Plan (Distance) 90 Figure 4.27 Pareto Charts Before Improvement (Time) 91 Figure 4.28 Pareto Charts Improvement Plan (Time) 92 Figure 4.29 Pareto Charts Before Improvement (Distance) 93 Figure 4.30 Pareto Charts Improvement Plan (Distance) 94 Figure 4.31 Lead Time Current Condition & Improvement Plan 99 Figure 4.32 Comparison Operating Cost for Current Condition &
Improvement Plan
101
Figure 5.1 Slump at "T" stands area 107
Figure 5.2 Broken at chamfering 107
Figure 5.3 Part Marking dirty and not clear 107
Figure 5.4 Filler not remove in drill hole. 108
Figure 5.5 Scratch mark 108
Figure 5.6 Dented 108
Figure 5.6 Pin hole 109
Figure 5.8 Damage 109
Figure 5.9 Filler not remove at edge 109
Figure 5.10 Paint run 110
Figure 5.11 Paint thin 110
Figure 5.12 Over spray 110
Figure 5.13 Illuminance at Part Marking/ QC Inspection Area 114
Figure 5.14 Illuminance at Sorting Area 115
Figure 5.15 Illuminance at Rework Area 116
Figure 5.16 Illuminance at Filler Area 117
Figure 5.19 Illuminance at Spray Booth #3 Area 120
Figure 5.20 Illuminance at Dry Sanding Area 121
Figure 5.21 Illuminance at Water Break Test Area 122
Figure 5.22 Illuminance at Masking Area 123
Figure 5.23 Chart of Noise level in Every Workstation of Painting Department
131
Figure 5.24 Area of Pain Aching or Discomfort for operator in Sorting Section
135
Figure 5.25 Area of Pain Aching or Discomfort for operator in Dry Sanding Section
136
Figure 5.26 Area of Pain Aching or Discomfort for operator in Water Break Test Section
137
Figure 5.27 Area of Pain Aching or Discomfort for operator in Filler Section
138
Figure 5.28 Area of Pain Aching or Discomfort for operator in Spray Booth Section.
139
Figure 5.29 Area of Pain Aching or Discomfort for operator in Oven Section
140
Figure 5.30 Area of Pain Aching or Discomfort for operator in Part Marking/QC Inspection Section.
141
Figure 5.31 Types of Treatment for Muscle Fatigue 143
Figure 5.32 Major Fatigue Muscle 144
LIST OF TABLES
Table 4.1 The Cycle Time of Each Panel in Dry Sanding Section 53 Table 4.2 The Cycle Time of Each Panel in Water Break Test
Section
55
Table 4.3 The Cycle Time of Each Panel in Sanding Filler Section 57 Table 4.4 The Cycle Time of Each Panel in Filler Section 59 Table 4.5 The Cycle Time of Each Panel in Primer Top 61 Table 4.6 The Cycle Time of Each Panel in Primer Bottom 63 Table 4.7 The Cycle Time of Each Panel in Grey / Antistatic 65 Table 4.8 The Cycle Time of Each Panel in Touch Up / Part Marking
Section
67
Table 4.9 The current operator for every panel 70 Table 4.10 Calculation of Operator Needed for Every Panel 71 Table 4.11 Proposed Area of the Workstation in Painting Department 75 Table 4.12 Comparison of Current Condition with Planned
Improvement (A320 Phase 1 Leading Edge (LE), Tailing Edge (TE), Aileron, Over Wing, Under Wing, A320/A321 - Affixed Fairing, Movable Fairing)
95
Table 4.13 Comparison of Current Condition with Planned
Improvement (A320 - ASSY Top Skin @ False Work)
95
Table 4.14 Comparison of Current Condition with Planned Improvement (A320 Spoiler)
96
Table 4.15 Target value and operation time (All Panel) 98
Table 5.1 Percentage of Defect Rate for Every Panel 111 Table 5.2 Illuminance/Light Intensity of Every Workstation 113 Table 5.3 Noise Level for Part Marking/QC Inspection Section 123
Table 5.4 Noise Level for Sorting Section 123
Table 5.5 Noise Level for Sorting Section 126
Table 5.7 Noise Level for Spray Booth #1, Spray Booth #2, Spray Booth #3
127
Table 5.8 Noise Level for Dry Sanding Section 128 Table 5.9 Noise Level for Water Break Test Section 129
Table 5.10 Noise Level for Oven 130
Table 5.11 The number of Operator/ Section who answered the Questionnaire
133
Table 5.12 Area of Pain Aching or Discomfort for Selected Operator in Every Workstation
134
Table 5.13 Type of Treatment 142
Table 5.14 Major of Fatigue Muscle 142
LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
CAD - Computer -Aided Design DML - Dedicated Manufacturing Line FFA - Factory Flow Analysis
FMS - Flexible Manufacturing System
GA - Group Analysis
IE - Industrial Engineering
LA - Line Analysis
MCM - Multi-Channel Manufacturing PFA - Production Flow Analysis QAP - Quadratic Assignment Problem SLP - Systematic Layout Planning
TA - Tooling Analysis
WIP - Work In Progress
Ft - Feet
ft.cd - Foot Candela
FMA - Factories and Machinery Act
OSHA - Occupational Safety and Health Act
LE - Leading Edge
TE - Tailing Edge
O/Wing - Over Wing
U/Wing - Under Wing
AFF - Affix Fairing
MF - Movable Fairing
LIST OF APPENDICES
A GANTT CHART FOR PSM
B TRADITIONAL TYPES OF FACILITY LAYOUT
C ALGORITHMS FOR PRODUCTION FLOW ANALYSIS
D MACHINE IN PAINTING DEPARTMENT
E: SUMMARIZE OF THESIS READING
F NORDIC MUSCULOSKELETAL QUESTAINAIRE
G FOURTH SCHEDULE OF FACTORY AND MACHINE ACT,
REGULATION 38 (FIRST AID BOX)
H SECOND SCHEDULE OF FACTORY AND MACHINE ACT,
REGULATION 28 (STANDARD OF LIGHTNING)
I FIRST SCHEDULE OF FACTORY AND MACHINE ACT,
