Manual process with 6 operators

Process Information

1. Cutting (the saw cuts tubes and rods for many FEI product families).  Manual process, 1 operator

 Cycle time = 15 seconds

 Changeover time = 15 minutes (length), 60 minutes (diameter)  Reliability = 100%

 Inventory

i. 20 days of uncut tubes

ii. 5 days of cut tubes.

2. Welding workstation 1 (dedicated to the hydraulic control sections product family)

 Welds the first machined casting to the tube

 Automatic process, with operator load and unload external to the

machine cycle

 Cycle time:

i. Operator = 10 seconds

ii. Machine = 30 seconds

 Changeover time = 15 minutes (length), 60 minutes (diameter)

 Reliability = 90%

 Inventory = 3 days of welded sections.

3. Welding workstation 2 (dedicated to the hydraulic control sections product family)

 welds the second machined casting to the tube

 Automatic process, with operator load and unload external to the

machine cycle

 Cycle time:

i. Operator = 10 seconds

ii. Machine = 30 seconds

 Changeover time = 15 minutes (length), 60 minutes (diameter)

 Reliability = 80%

 Inventory = 3 days of welded sections.

4. Deflash workstation (dedicated to the hydraulic control sections product family)

 Automatic process, with operator load and unload external to the machine cycle

 Cycle time:

i. Operator = 10 seconds

ii. Machine = 30 seconds

 Changeover time = 15 minutes (length), 60 minutes (diameter)

 Reliability = 100%

 Inventory = 5 days of deflashed sections.

5. Painting (hydraulic control sections are shipped to an outside contractor for painting)

 Painting lead time = 2 days

 One daily truck pickup of unpainted sections and drop-off of painted

sections

 Observed inventory:

i. 2 days at the painter

ii. 6 days of painted sections at FEI.

6. Connector assembly (dedicated to the hydraulic control sections product family)

 Manual process with 6 operators

 Total Work Time per Piece = 195 seconds

 Changeover time = 10 minutes fixture swap

 Reliability = 100%

 Observed finished goods inventory in warehouse = 4 days of finished

hydraulic control sections.

7. Machining of Castings (dedicated to the hydraulic control sections product family)

 Automatic machining process with one machine attendant  Cycle time = 30 seconds

 Changeover time = 2 hours

 Reliability = 100%

 Observed inventory:

i. 20 days of raw castings from the supplier

ii. 4 days of machined castings.

8. Despatch department

 Removes parts from finished goods warehouse and stages them for truck shipment to customers.