World class manufacturing during prototyping for production
type: CreativeWork
description: The transition from prototype to production affects impacts cost and scalability and contributes to the organizational culture. Since, the implementation of World Class Manufacturing (WCM) during prototyping has not been well document; this thesis examines applying WCM tools and techniques to foster a Lean culture by selecting, and optimizing the assembly process, integrating Enterprise Resource Planning (ERP) system, developing standard operating procedures, continually improving processes and adapting facility layouts, along with assessing ergonomic factors. The management team selected a modular assembly which allowed uncoupling workstations, un-synchronizing movements, improving changeability for agility, and lowering lead times. The effect balanced the production process. The assembly process was optimized by developing detailed assembly work instructions and training tools. A facility plan layouts and Value Stream Mapping (VSM) were also prepared for analysing cycle, lead, and Takt times. For the first VSM's value-added and non-value-added times were 11:37 and 1:25 (hours:minutes), respectively. The material travel distance within the facility was reduced by 11% from the initial layout to the third iteration despite floor space increasing. Improving ergonomics in the workplace included fabricating or modifying assembly and material carts, introducing anti-fatigue mats, and designing new modular, SA workstations. Assembler assessments for both the SA and GA workstations were completed using the Rapid Entire Body Assessment (REBA) and Rapid Upper Limb Assessment (RULA). For inventory management and pull system implementation, Kanban along with Point of Use Inventory (POUI) was introduced; item and Kanban cards were developed. The bin quantity calculation suggested allocating a 2-bin system for Kanban. The POUI for fasteners and hardware items were vendor-managed inventory by Fastenal Company. The fuzzy Decision-Making Trial and Evaluation Laboratory (DMATEL) ana…
abstract: The transition from prototype to production affects impacts cost and scalability and contributes to the organizational culture. Since, the implementation of World Class Manufacturing (WCM) during prototyping has not been well document; this thesis examines applying WCM tools and techniques to foster a Lean culture by selecting, and optimizing the assembly process, integrating Enterprise Resource Planning (ERP) system, developing standard operating procedures, continually improving processes and adapting facility layouts, along with assessing ergonomic factors. The management team selected a modular assembly which allowed uncoupling workstations, un-synchronizing movements, improving changeability for agility, and lowering lead times. The effect balanced the production process. The assembly process was optimized by developing detailed assembly work instructions and training tools. A facility plan layouts and Value Stream Mapping (VSM) were also prepared for analysing cycle, lead, and Takt times. For the first VSM's value-added and non-value-added times were 11:37 and 1:25 (hours:minutes), respectively. The material travel distance within the facility was reduced by 11% from the initial layout to the third iteration despite floor space increasing. Improving ergonomics in the workplace included fabricating or modifying assembly and material carts, introducing anti-fatigue mats, and designing new modular, SA workstations. Assembler assessments for both the SA and GA workstations were completed using the Rapid Entire Body Assessment (REBA) and Rapid Upper Limb Assessment (RULA). For inventory management and pull system implementation, Kanban along with Point of Use Inventory (POUI) was introduced; item and Kanban cards were developed. The bin quantity calculation suggested allocating a 2-bin system for Kanban. The POUI for fasteners and hardware items were vendor-managed inventory by Fastenal Company. The fuzzy Decision-Making Trial and Evaluation Laboratory (DMATEL) ana…
author: Jarry, Jaspreet Singh
language: en
date published: 2023-08
date modified: 2026-07-24T04:03:49Z
provider: University of Regina
publisher: Networked Digital Library of Theses and Dissertations
type: WebPage
source organization: Faculty of Graduate Studies and Research, University of Regina

PropertyValue
property ID: Handle
value: https://hdl.handle.net/10294/16492

PropertyValue
property ID: DOI
value: 10.82465/5013