Small Scale Manufacturing Exercise

1
Small Scale Manufacturing Exercise - Job
Descriptions
2
Business Simulation Activity
Material Handlers - Job Description

• Responsibilities.
• Store and distribute tools and materials
• Move in-process materials around tables
• Account for all paper blank usage
• Keep running tally
• Produce finalised Tally
• Minimise in-process inventory

• Materials Tools.
• Red and white paper blanks
• Scissors
• Pencils
• Rulers
• Blue felt-tip pens.
• Templates

3
Business Simulation Activity
Cutters - Job Description

• Responsibilities.
• Cut equal numbers of red and white paper (into
  squares 21cm x 21cm)

• Materials Tools.
• Red and white paper blanks
• Scissors
• Pencils
• Rulers

4
Business Simulation Activity
Folders A - Job Description

• Responsibilities.
• Fold the A section of the Frisbee according to
  the attached instructions

• Materials Tools.
• Red Paper squares
• Folding instructions

5
Business Simulation Activity
Instructions for Folder A
Step 1
Step 2
Step 3
Fold
Fold
Crease
Step 6
Step 5
Step 4
Fold
Fold
Fold
Fold
6
Business Simulation Activity
Folders B - Job Description

• Responsibilities.
• Fold the B section of the Frisbee according to
  the attached instructions.

• Materials Tools.
• White Paper squares
• Folding instructions

7
Business Simulation Activity
Instructions for Folder B
Step 1
Step 2
Step 3
Fold
Crease
Step 6
Step 5
Fold
Fold
Fold
Fold
8
Business Simulation Activity
Final Assemblers - Job Description

• Responsibilities.
• Join and fold the A B sections of the
  Frisbee according to the
• attached instructions.

• Materials Tools.
• Folded A Section (RED)
• Folded B Section (WHITE)
• Folding instructions

9
Business Simulation Activity
Instructions for Final Assemblers
Piece B
Step 2
Step 1
Piece A
Fold
B
B
Turn piece over.
Place B on A. Tuck points on A into flap in B.
A
A
Fold
B
Fold
Step 3
Finished Frisbee
A
Tuck points on B into flap in A.
Fold
10
Business Simulation Activity
Painters - Job Description

• Responsibilities.
• Paint the two decorative blue wedges on one side
  of the Frisbee, only as
• outlined in the attached instructions.
• Paint must be neat and of a density and standard
  comparable to the
• sample.

• Materials Tools.
• Folded Frisbee
• Blue Felt-tip pen
• Metal Template (5 cm in diameter)

11
Business Simulation Activity
Instructions for Painter
Paint the decorative blue wedges on one side of
the Frisbee only as shown
12
Business Simulation Activity
Quality Control Inspectors - Job Description

• Responsibilities.
• Ensure standards are maintained during the
  manufacturing process.
• Give feedback to production staff and advise on
  quality when appropriate.
• Ensure final product meets all specified
  standards, for quality and specification.
• Deliver finished, inspected Frisbee to customer

• Materials Tools.
• Sample Frisbee
• Quality Standards
• All fold neat
• No tears, smudges, unspecified creases or dents.
• Equal angles between points
• Blue wedges are painted in the specified side
  and section, neatly and of good density.

13
Small Scale Manufacturing Exercise
14
Business Simulation Activity
The Situation.
Frisbees are as popular today, with all ages, as
they ever were. Although the market is highly
competitive, our Frisbee design, with its unique
shape and aerodynamic characteristics, is in high
demand. Customers will buy all that can be
produced, provided the product is manufactured to
the same high quality and standard as the sample.
Therefore if the product is to remain successful
everyone must undertake their job with not only
with vigour but also with care.
15
Business Simulation Activity
The Organisation. (Page 1) The following
activities need to be undertaken to produce a
flying Frisbee. As a TEAM you should decide how
to organise yourselves and whether to have a
supervisor or not.

• Responsibilities.
• Materials Handlers
• Store and distribute tools and materials
• Move in-process materials around tables
• Account for all paper blank usage
• Keep running tally
• Produce finalised Tally
• Minimise in-process inventory
• Cutters
• Cut equal numbers of red and white paper (into
  squares 21cm x 21cm)
• Folders A
• Fold materials according to A instructions
• Folders B
• Fold materials according to B instructions

• Materials Tools.
• Red and white paper blanks, ?Scissors, ?Pencils,
  ?Rulers, ?Blue felt-tip pens.
• Red and white paper blanks, ?Scissors, ?Pencils,
  ?Rulers
• Red paper blanks, ?Folding instructions.
• Red paper blanks, ?Folding instructions.

16
Business Simulation Activity
The Organisation. (Page 2)

• Responsibilities.
• Final Assemblers
• Join and fold A and B sections into final Frisbee
  according to instruction sheet.
• Painters
• Using template, pencil and blue felt-tip pen
  apply decoration to Frisbee as per the sample.
• Quality Control Inspectors
• Ensure standards are maintained during the
  manufacturing process.
• Give feedback to production staff and advise
  when appropriate.
• Ensure final product meets all specified
  standards, for quality and specification.
• Deliver finished, inspected Frisbee to customer.

• Materials Tools.
• A B folded paper sections, ?Folding
  instructions
• Folded Frisbee, ?Blue felt-tip pens, ?Pencils,
  ?Metal circle/template, ?Painting instructions.
• Quality standards, ?Sample Frisbee.

17
Business Simulation Activity
The Ground Rules.

• Production Goal
• To produce the maximum number of high-quality
  Frisbees.

• Production Performance Measures
• The number of Frisbees accepted by customer.
• Material Yield Frisbees accepted by
  customer x 100
• Cut paper blanks in process 2
• Quality Standards
• All folds must be neat.
• No tears, smudges, unspecified creases or dents.
• Equal angles between points.
• Painting as shown on the sample.
• Units will only be considered complete when
  accepted by the customer.

18
Business Simulation Activity
Materials Listing.
Each Factory should have -

• Sample Frisbee.
• Handouts.
• 2 x Pairs Scissors.
• 3 x Rulers.
• 1 x Template.
• 4 x Blue Felt-tip Pens.
• 4 x Pencils.
• 20 x Red Sheets of Paper.
• 20 x White Sheets of Paper.

19
Business Simulation Activity
Scenario 1 - Absence from Work

• The Final Assembler has just telephoned in sick,
  he/she has had an accident at home and will be
  off work for some time.
• Final Assembler, please leave your team for a
  penalty
• period, instructions will be given to you by a
  facilitator.
• Please wait for the facilitator to ask you to
  re-join your
• team

20
Business Simulation Activity
Scenario 2 - Absence from Work

• The Assembler A has just received a telephone
  call informing him there has been an incident,
  involving a burst water pipe at home. He is
  required immediately and will be absent for the
  remainder of the day.
• Assembler A please leave your team for a
  penalty
• period, instructions will be given to you by a
  facilitator.
• Please wait for the facilitator to ask you to
  re-join your
• team

21
Business Simulation Activity
Scenario 3 - Absence from Work

• The Assembler B has just telephoned to inform
  his/her supervisor that his/her daughter is ill
  and he/she is needs to look after her. He has
  been granted leave on compassionate grounds and
  will be absent for at least two days.
• Assembler B please leave your team for a
  penalty
• period, instructions will be given to you by a
  facilitator.
• Please wait for the facilitator to ask you to
  re-join your
• team

22
Business Simulation Activity
Scenario 4 - Tool Calibration.

• The Colouring template is due for its annual
  calibration checks/tests.
• The painting operation is therefore unable to
  continue until this exercise is completed and
  because the painters assistance is also required
  he/she will be unavailable for the same time.
• Painter please leave your team for a penalty
  period, taking
• with you your metal template. Any further
  instructions will
• be given to you by a facilitator.
• Please wait for the facilitator to ask you to
  re-join your
• team

23
Business Simulation Activity
Scenario 5 - H.S.E. Assessments.

• The cutting equipment has been flagged, requiring
  small adjustments and checking and will therefore
  be withdrawn from use during this exercise and
  because the cutters assistance is also required
  he/she will be unavailable for the same time.
• Cutter please leave your team for a penalty
  period, taking
• with you all pairs of scissors. Any further
  instructions will
• be given to you by a facilitator.
• Please wait for the facilitator to ask you to
  re-join your
• team.

24
Business Simulation Activity
Facilitator (Review) Hand-out.

• A. Organisation
• How did they organise their Team?
• What options did they consider ?
• How did they decide on team roles ?
• If they appointed a leader how did they come to
  their decision ?
• If they appointed a leader what role did they
  carry out ? i.e. was it the right choice ? - how
  did the others feel about it ?
• How did they plan for the activity ? or did they
  ?
• B. Goals
• What prevented the Team from meeting its
  objectives even more effectively than they did ?
• What kind of errors crept into its operation ?
  What were the causes ?
• C. Impact of/on others
• What did team members do to support each other,
  individually and as a group ?
• What did they do to hamper each other,
  individually and as a group ?
• What activities caused errors ?
• D. Control (individuals)
• Which aspects did each team member feel were out
  of their control during production ?

25
Business Simulation Activity
Customer Hand-out.

• You are responsible for the receipt of products
  into your factory, as such you must ensure they
  meet your companies high standards.
• Acceptable Frisbees should be initialled and
  placed in the appropriate teams bag.
• Unacceptable Frisbees should be discarded in the
  bin bag supplied
• You can reject items, after initialling, for
  minor corrections/re-work, but only once.
• If they still fail to meet standard they are
  classed as unacceptable.
• N.B. Remember the key Quality Standards issues -
• All neat folds
• No tears, smudges, unspecified creases or dents.
• Equal angles between points.
• Blue wedges are painted on the correct side, as
  per sample and that they are neat
• and of good density.