-20320-623570 Unit 68: Lean Production System Design 2023/24
-20320-623570 Unit 68: Lean Production System Design 2023/24
- 23/24
00 Unit 68: Lean Production System Design 2023/24
- 23/24
1859280-297180
BTEC Assignment Brief
Qualification Pearson BTEC Level 3 Diploma in
Engineering. Academic Year: 2023/2024
Unit or Component number and title Unit 68: Lean Production System Design
Learning aim(s)
(For NQF/RQF only) Outcome Covered: 1 - Know the principles of lean manufacturing
Assignment title Assignment 1: Lean Manufacturing
Assessor David Cartwright
Hand out date 23rd November 2023
Hand in deadline 7th December 2023
Vocational Scenario or Context Assignment Introduction
Scenario
You are an apprentice doing 3 month placements in a range of departments at your company. You are currently working in the production planning department and your Managing Director has asked you to advise the company on some issues they are facing. Many companies apply Lean techniques as it is important to be cost effective and efficient in manufacturing processes to insure companies stay competitive in todays market. The activities shown below will help you gather data and gain knowledge and help in this regard so that you can advise your Managing Director accordingly about how Lean manufacturing can be applied in a engineering workplace.
Task 1 Task 1
(P1)
Define waste in terms of value.
Describe 4 of the 8 areas of waste that can be found in a production system and give an example of each. The examples of waste can be taken from your own workplace, or from a production system that is familiar and easy to observe eg. a fast-food chain. You could include photographs to help your descriptions.
Also, identify some of the hidden costs of holding a large inventory of finished goods.
A large manufacturing group such as Ford or VAG (Volkswagen-Audi Group) might use group technology to improve product quality, meet rising customer demands and reduce manufacturing costs. Describe the techniques they might use to classify parts/product families and the benefits this will give.
(P
(M1)
Research (using motoring publications, articles etc.) at least 3 examples of where an Automotive Manufacturer has actually used a common platform, major systems (engine, transmission etc.) or shared parts to launch a new vehicle or model that greatly benefits from technology already available within its own group. Specify the common or group technology items they have used to deliver a new product to the market/customer. Explain the benefits they have gained by doing this.
Checklist of evidence required (P1) a) Define what Waste is in terms of value:
How does waste affect the company.
How does waste affect the customer.
How can a manufacturer add value to their products.
b) Describe 4 of the 8 wastes:
Describe the wastes you have chosen.
How does the waste affect the company.
How does it affect the customer.
Give an example for each waste.
c) Hidden costs of holding large inventory:
Describe how holding inventory can affect a businesss cashflow.
Give 5 examples of costs involved with holding large inventory.
Make sure you describe each cost in detail.
d) Group Technology:
Written description of what Group Technology (GP) is.
List some of the characteristics used in GP to classify components.
Fully describe the Opitz classification system with images.
Fully describe the MiClass classification system with images.
(M1) Researched examples of Group Technology:
Us the internet or sales brochures to research 3 examples of where automotive companies have shared common platforms, major systems (Engine, Gearbox, chassis) or parts to bring a new product to the market.
Each example must be accompanied with evidence such as brochures, website addresses or book references.
Each of the 3 examples should have a written description of what the component is and how both vehicles use it.
For each example describe how the manufacturers benefit from sharing that component.
Criteria covered by this task:
Unit/Criteria reference To achieve the criteria, you must show that you are able to:
P1 Describe the principles of minimising waste and the techniques of group technology
M1 Explain the benefits of applying group technology to a production system
Task 2 Task 2
(P2)
Describe a diagram that helps demonstrate Continuous Improvement using the Deming (PDCA) cycle that shows how small (and inexpensive) improvements can be sustained or held over time to improve a product or process. Briefly describe how Continuous Improvement activities will benefit a company.
Describe how you might use Visual Management so that all co-workers and departments are able to understand, share and benefit from them to sustain improvements in the workplace. Illustrate this with at least 2 suggestions of how and where you might share key information. Again photographs can be included.
(P
(D1)
(D1)
Compare and contrast the differences in making small, sustainable improvements to a process against that of large and expensive changes. Consider how a small incremental approach differs to that of large step changes. Consider both the business and human aspects of making changes in the workplace in your discussion.
(D1)
Checklist of evidence required (P2) a) Describe the PDCA cycle:
Give a written description of the 4 stages of the PDCA cycle.
Add an image of the PDCA cycle. (Remember to reference the image)
Explain how the PDCA cycle can help sustain small changes
Describe how carrying out Continuous Improvement activities can help a company improve.
b) Visual Management:
Describe why you might use Visual Management at work to help share key information.
Give at least 2 examples of where you might use Visual Management at work or the MGTS workshop.
Describe what key information is shared in your examples and how this will benefit everyone using it.
In your report use images to help illustrate your types of Visual Management chosen. (Remember to reference the images)
(D1) Compare the differences between small and large step changes:
You written comparison should include
Advantages / Disadvantages of small changes in the workplace.
Advantages / Disadvantages of large changes in the workplace.
Cost of changes
Employee engagement
Reverting back if change has not worked
Employee driven ideas
Sustainable step changes
Criteria covered by this task:
Unit/Criteria reference To achieve the criteria, you must show that you are able to:
P2 Describe the reasons for maintaining a specified engineering system.
D1 Describe four maintenance activities for a specified engineering system.
Task 3 Task 3
(P3)
Describe the principles and advantages of a pull production system.
Describe the meaning of a place for everything, and everything in its place with at least 3 examples of workplace organization. Try to do this based on your own workplace, the workshop at MGTS or if not, use that of a McDonalds Restaurant.
(P3)
Checklist of evidence required (P3) a) Describe the advantages of a Pull production system:
Give a brief description of
What is Push production
What is Pull production
List the advantages of Pull production
b) Workplace Organisation :
Describe what the sentence a place for everything and everything in its place means .
Refer to what you have learnt about 5s and workplace organisation.
Give 3 examples of workplace organisation for your place of work or the MGTS workshop.
Provide images of your chosen workplace organisation
Criteria covered by this task:
Unit/Criteria reference To achieve the criteria, you must show that you are able to:
P3 Describe the reasons for maintaining a specified engineering system.
Sources of information to support you with this Assignment Class notes, Moodle resources, internet, and company information.
Other assessment materials attached to this Assignment Brief FOR L1/2 FIRSTS ONLY: If you have not achieved the Level 2 criteria, your work will be assessed to determine if the following Level 1 criteria have been met.
To achieve the criteria, you must show that you are able to: Unit Criterion reference
