Layout planning of assembly areas for optical systems

Abstract

The Eagle Eye Locating System is an innovative product, with significant international sales potential. For the manufacturer, Carl Zeiss Optronics Ltd (Pty), it is essential that the product should be of high quality and reliability. Marketing of the product concepts has already indicated an initial demand. Meeting the demand timeously is important since the technology is already in the public domain and could be copied by competitors. This product is complex, and is currently assembled in batches, with the assembly line showing no signs of stable flow and consequently unable to achieve the desired production rate. Zeiss has decided to rearrange the production facility, and dedicate specific workstations and personnel to the assembly of the Eagle Eye, removing the risk of production floor congestion. In this document it is shown how various techniques have been used to draw a proposed facility layout that could sustain a stable assembly flow. The proposed locations of the workstations inside the assembly area have been mapped. Not only the material movement, but also the important communication flows between the workstations have been incorporated. The best alternative layout has been selected with supporting simulations. A simulation showing the total cycle time at each workstation has been used to determine the effect of uncertain operation times and the balance of workload at each workstation. The actions to balance the cycle times and proposed close proximity of applicable workstations could ensure an optimal stable flow of assembly. With a stable production flow established the sub-assemblies will not need to be moved to the store room for safety, decreasing inventory levels, material movement and labour required. Overall the throughput will be increased and the forecasted demand can be satisfied. If the proposed actions are taken the total time required to produce a batch of ten Eagle Eyes will be reduced by ten man hours.