Classic Productivity Systems for the Assembly Manufacturer or Distribution Center

iUniverse, Inc.

Contents

1 THE CONSULTANT..................................................................................62 OPERATIONS AUDIT................................................................................93 SURVEY AND REPORT (WHAT THE ROI ANALYSIS' MAJOR COMPONENTS SHOULD RESEMBLE).....................384 CLASSIC PRODUCTIVITY SYSTEMS (WHAT THE ROI ANALYSIS SHOULD INCLUDE).............................705 CASE HISTORIES..................................................................................1856 YOUR PRODUCTIVITY EVALUATION....................................................................2027 THE STANDARDS GUIDE.............................................................................2208 PACED ASSEMBLY WITHROBOTIC WORK CELLS...........................................................2339 STANDARD IMPLEMENTATION PROCEDURES..............................................................25610 MATERIALS HANDLING SIZING AND COSTING DIALS....................................................28011 GRASP CONVEYOR SYSTEM CONFIGURATIONS...........................................................28112 BIBLIOGRAPHY...................................................................................304

Chapter One

Thank you for your purchase of our CLASSIC PRODUCTIVITY SYSTEMS Book. As noted on the cover, Revision A contains our generic industrial engineering proposals should your company seek outside expertise in your improvement effort. Since you have chosen Revision A, congratulations, as we guarantee your savings will offset our fees within the first year should you decide to use us in your cost reduction efforts. Our proven track record, concentrated effort, objectivity with no dilution of your own personnel will result in earlier realized gains.

Classic Productivity Systems is a collection of labor and space optimization techniques and examples of various return-on-investment scenarios designed to assist the industrial sector in being cost competitive. It is a detailed modernization return-on-investment exercise in the stockroom, fabrication, assembly, work-in-process, finished goods departments and addresses materials handling mechanization & product automation feasibility as well as classical direct labor control systems.

JD Gray Associates has developed a two phased approach designed especially for each clients requirements:

OPERATIONS AUDIT. Our industrial engineering critique of plant-wide operations determines a cost reduction master plan.

Our Operations Audit will develop materials handling configurations, work cell automation types and classical direct labor controls systems that are best used with assembly manufacturers or distribution centers. It is the first and most critical step in cost reduction as it is performed prior to materials handling or automation equipment purchase to enable the client to view mechanization alternatives with paybacks for each scenario. This is an industrial engineering critique of plant-wide operations and includes thru put analysis, staffing, plant wide-departmental-work station layout, equipment specifications-request for quotations-quotations, semi-automation tooling, detailed productivity recommendations, alternative material handling systems, outline of consulting services, comparison of savings versus cost & phased modular segments of our recommended systems.

As a result of the completion of our Operations Audit ... concentrated effort will have been paid to the classical productivity areas of materials handling, work-in-process storage and tracking, semi-automatic machinery, paced assembly, short-interval-scheduling, labor reporting, industrial engineered standards and methods & industrial incentives ... and sub proposals will be generated where the return-on-investment is greatest.

We have provided samples of the major Operations Audit sections including the personnel summary, the implementation `action required' section, layout, the savings and cost section and the executive summary as well as step by step preparation procedures so you can create your own Operations Audit if you so choose. We have also provided the final documents of some of our installed consulting activities including printed circuit board insertion time values entitled The Standards Guide, a workstation visual aid, workstation line balancing, final materials handling equipment specifications, a sample of the control panel preset dwell time by model, implementation follow-up, final component automation equipment specifications, short run scheduling and a paced assembly manufacturing procedure. JD Gray Associates' materials handling live storage and retrieval carousel and transporter sizing dial fliers, our budget costing and investment return dial flier for assembly and storage conveyors and our Grasp conveyor system configuration fliers have been supplied. Case Studies have also been provided where a few of our Classic Productivity Systems have been installed.

IMPLEMENTATION. All required industrial, mechanical and electrical engineering services to ensure the proper functioning of purchased hardware. These activities are always outlined and costed in the Operations Audit generated report but can be performed exclusive of same if desired.

We have also prepared separate questionnaires for the assembly manufacturer, the printed circuit board manufacturer and the distribution center ... from a classical industrial engineering viewpoint. How efficient is your operation? Take our QUIZ and see!

We would like to acknowledge the following companies having used excerpts from their articles, books or quotations: H.B. Maynard and Company Inc., Industrial Time Study Institute, Managers-Net, Alexander Proudfoot, Kepner-Tregoe Inc, Phoenix Welding, White Systems, Buschman Conveyors, Diamond Phoenix, Institute of Industrial Engineers, Versa-Tech Automation and the former Alden Systems.

JOSEPH D GRAY

Joseph D. Gray is the Director of JD Gray Associates. He has more than 30 years experience in industrial engineering, product automation, materials handling and lean manufacturing management and specializes in the following areas:

Labor standards Labor standards and Performance Based Performance Based and methods for methods for Payment Chart and Payment System Manufacturing Distribution Centers Manufacturer and Distribution Center

Plant layout Staffing analyses Just-In-Time Industrial Incentive techniques systems

Short-Interval- Lean Paced Pick and pack Automation of Scheduling and Assembly Lines - warehouse systems assembly work cells labor reporting Line Balance - Method of Assembly

Mr. Gray has pioneered the design and implementation of a controlled work atmosphere in assembly and machining systems, and his designs frequently save clients 30% to 50% in labor costs and factory space. He also has significant experience in work-in-process inventory reduction, stockroom design and operations.

As a consultant, he has worked...