TEAMSKILL an exploration of manufacturing

1
TEAMSKILLan exploration of manufacturing

• The development of this simulation was sponsored
  by Honeywell and Metal Working Production
  magazine and run twice as a National Production
  Management Contest in the UK.

2
Introduction

• You manage the operation of a factory.
• Planning the Factory
• Scheduling Materials and Production
• Inventory Management
• Production Control
• Ensuring Timely and Efficient Operation

3
Process

• You will be divided into small teams each of
  which must
• Analyze the situation
• Plan the Factory
• Run the Factory for several Months
• Combine with the other teams to discuss and
  compare results and strategies

4
The Situation

• The factory that you are to manage makes small
  electric motors
• The factory is about to move to a new site and
  this gives you the opportunity to replace
  machinery, change layouts, etc.
• And this move means that you are replacing the
  existing, senior manufacturing management.

5
The Roles

• Although you are free to organise your team in
  any way you wish, your responsibilities are
  likely to include
• Works Manager (team leader)
• Production Manager
• Inventory Control Manager
• Manufacturing Cost Accountant
• Industrial Engineering Manager

6
The Product

• The Electric Motor consists of these main parts
• Stator
• Rotor
• Frame
• And there are five models
• 240/220 Volt long frame
• 240/220 Volt short frame
• 117 Volt long frame
• 117 Volt short frame
• 240/117 Volt long frame

7
The Production Units

• You will manage in detail these manufacturing
  units
• Punch Press (turns steel strip into punchings)
• Rotor Assembly (uses punchings aluminum)
• Stator Assembly (uses punchings wire)
• Final Assembly (uses stators, rotors frames)

8
The Materials

• You will manage in detail these materials
• Steel Strip (magnetic motor elements)
• Aluminum (electrical rotor elements)
• Copper Wire (electrical stator elements)
• Casting Sets (motor frame)

9
Production Process
SS
PP
RP
CW
A
SP
SA
RA
F
S
R
Raw Materials
FA
In Process Materials
Finished Products
FM
10
Decisions

• decide a team name (up to six letters)
• for the first period make planning decisions
• for all periods schedule the factory

11
Factory Planning Decisions

• Punch Press Machine
• Die Cast Layout
• Number of Stator Lines
• Stator Staffing
• Casting Set Supplier
• Optional Reports
• Storage Area Sizes

12
Factory Scheduling Decisions

• Material Purchases
• Minimum Production Rates
• Maintenance Frequency
• Machine Set-Ups
• Final Assembly Schedule
• Days Shutdown

13
Results

• Decisions
• Manufacturing Account
• Capital Statement
• Production Summary
• Customer Research
• Inventories (at month end)
• Optional Reports
• Comments
• Current Set-Ups (end of month)

14
Observations

• it takes time to understand
• but the factory still must be run
• so your decisions will not be perfect
• time will be a constraint
• but, by the end you should be just in command of
  your business!
• your business competencies will be challenged
• make sure you use the talents of your fellow team
  members
• ensure that you allow time to reflect