Coventry University | Lean Manufacturing 2012

COVENTRYUNIVERSITY
FACULTYOFENGINEERING&COMPUTING

CaseStudy
Brockhurst Automotive
Parts(BAP)

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Coventry University | Lean Manufacturing 2012

BrockhurstAutomotiveParts(BAP)
ClassCaseStudy

Introduction

BrookAutomotiveParts(BAP)isamanufacturingcompanybasedintheMidlands.Itmanufactures
metalpressingsandfabricationsforhighvolumeautomotivecustomers.Itscurrentmanufacturing
processesincludepressworkandresistanceandspotwelding.

BAP'smanufacturingfacilityiscurrentlyproducingtomassproductionprinciples.The
machineshaveafunctionallayout(figure1)andproducecomponentsinlargebatches.

Aninitialanalysisofthecompanyproductiondatahasidentifiedaproductfamilycontainingtwo
parts,AZ123andAZ234,whicharehighvalue,highvolume,runnerproducts,whichsharethesame
processroute.

Analysethefollowinginformationtocriticallyappraisethecurrentstateofthecompany.

BrookAutomotiveParts(BAP)MaterialandinformationFlow

CustomerRequirements
20,000subassembliespermonth:
12,700permonthAZ123
7,300permonthAZ234
Returnable frame boxes (universal for AZ123 and AZ234), 20 frames per box, 10 boxes per
carrier.
Oneshipmentperdaytothecustomerbylorry.
Customersiteworkingtwoshiftsystem(6amuntil2pmand2pmuntil10pm)

ProductionProcesses
BAP'sprocessesfortheframeproductfamilystartswithpressingtheblank,followedbyfinish
pressing.Thepressshopusesabatchsizeof10,000every2weeks(EPE2weeks).Thebatches
arethentransportedtotheweldingareabyforklifttrucks.
The use of high batch size and the distant location of the supplier of pressed components
usually results in the welding area experiencing a feast and famine situation. The batch size
used in the welding area is determined by the carriers, ie 200. The carrier is then moved
manuallytotheassemblyareawhereitisassembledandsubsidiarydrillandtapoperationsare
carriedout.

Afterassemblytheframesaresenttogoodsoutwardstobesenttoaplatingsubcontractor.The
normal quantity despatched is 2000 and the despatch timing is sporadic, depending on when
thestockisavailabletogoout.Thetumroundtimeisquotedas2days,howevertheprocess
timeisonly30minsperbatchof500.

The frames are returned to Good inwards and then proceed to an insert operation, an
automatictestandfinallylabelandpack.
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AschematiclayoutoftheshopfloorisgiveninFigure1.Finishedframesarethenstagedand
shippedtothecustomer'ssitedaily.

LanchesterSteelsLtdsupply'ssteelcoilstoBAPonMondaysandFridays.

WorkTime

20workingdaysinamonth.
Operatinga2shiftsysteminallproductionoperations.
8hourspershiftwithone30minutebreakeachshift.
Manualprocessesstopduringbreaktimes.

ProductionControl

This is the responsibility of the BAP Logistics department which receives 90/60/30 forecasts
from the customer. Logistics are responsible for downloading this information onto the MRP
system.
A4weekforecastisissuedbylogisticstoLanchesterSteelsviaMRP.
LogisticsensuresteelisavailableandsecuressteelbyweeklyfaxedorderreleasetoLanchester
Steelsltd.
BAPgeneratesweeklydepartmentalrequirementsviaMRP.
Adailyfirmorderisreceivedfromthecustomer.
WeeklyrequirementsarecustomerorderbasedaswellaslogisticstakingintoaccountWIPand
finishedgoodsinventorynumbers,anticipatedscrapandprocessdowntime.
LogisticsissueweeklybuildscheduletothePressShop,Welding,Assemblymachining,testand
pack.
LogisticsissueadailyshippingplantotheDespatchDepartment.

BrookAutomotiveParts(BAP)ProcessData

Operation1FinishPressing(notdedicatedtoproductfamily)

300tonmanualpress
CycleTime:

4seconds(15finishedpressingperminute)
ChangeOverTime:

32minutes(includingFirstoffpassoff)
PressAvailability:

85%
EPE:

2weeks
QualityPassRate:

93%
ObservedInventory:
5dayscoilsbeforepressing
5.200AZ123finished
2.900AZ234finished

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Operation2SpotWeldWorkstation1

Oneoperatordedicatedtomanualprocess
CycleTime:

70seconds
ChangeOverTime:
15minutes(fixturechange,includingfirstoff)
WeldingMachineAvailability:
100%
Qualitypassrate:

98%

ObservedInventory:
3.600AZ123
1.000AZ234

Operation3Assembly

Oneoperatordedicatedtomanualprocess
CycleTime:

65seconds
ChangeOverTime:
nil
MachineAvailability:
100%
Qualitypassrate:

95%

ObservedInventory:
2.450AZ123
1.600AZ234

Operation4Drill

Oneoperatordedicatedtomanualprocess
CycleTime:

10seconds
ChangeOverTime:
15minutes
MachineAvailability:
98%
Qualitypassrate:

95%

ObservedInventory:
4.650AZ123
2.750AZ234

Operation5Tap

Oneoperatordedicatedtomanualprocess
CycleTime:

15seconds
ChangeOverTime:
30minutes
MachineAvailability:
88%
Qualitypassrate:

95%

ObservedInventory:
2.900AZ123
1.550AZ234

Operation6Plating

CycleTime:

30minutesperbatchof500
2dayturnaroundtime
ChangeOverTime:
none
Availability:

100%
Qualitypassrate:

95%

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ObservedInventory:

Goodsout
3.150AZ123
1.850AZ234

Goodsin(tonextprocessInsert)
4500AZ123
2500AZ234

Operation7Insert

Oneoperatordedicatedtomanualprocess
CycleTime:

16seconds
ChangeOverTime:
15minutes
MachineAvailability:
85%
Qualitypassrate:

98%

ObservedInventory:
1.900AZ123
2.350AZ234

Operation8AutoTest

Oneoperatordedicatedtomanualprocess
LoadandUnload:

20seconds
AutomaticCycleTime:

30seconds
ChangeOverTime:
30minutes
MachineAvailability:
88%
Qualitypassrate:

95%

ObservedInventory:
2.750AZ123
1.850AZ234

Operation9Labelandpack

Oneoperatordedicatedtomanualprocess
CycleTime:

8seconds
ChangeOverTime:
nil
MachineAvailability:
100%
Qualitypassrate:

100%

ObservedInventory:
1.250AZ123
750AZ234

DespatchDepartment
Takepartsfromfinishedgoodslocationandstagesthemforshipmenttocustomervialorry.

FinishedGoodInventory
10.500AZ123
4.300AZ234

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Coventry University | Lean Manufacturing 2012

ACTIVITY1

1. MapthecurrentstateofBrockhurstAutomotiveParts(BAP).
2. Lookatthecurrentstatemapandtrytocriticallyappraisethecurrentsituation.
Appendix
Layout
Goods In/Out

Press

Weld

Tap
Assembly

Drill
Auto Test
Insert

Station

Label & Pack

Task

Time

Cumulative
Time

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Time

YamazumiBoard

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