Sunwind Case Study Solution

In partnership with: __________________________________________________
Sunwind AB:
A Case Study

School of Engineering
Trinity College Dublin

Report By
Eoin Mongey
Jack McDermot
Conal Campion

November 2014

Table of Contents Cover Letter Executive Summary

Preface

Internal Manufacturing analysis

Current Capacity at Save Current capacity of each process for each of the four panels Capacity of each process for a complete floor lid Effect on each process of running 1, 2 and 3 shifts

Assessment of capacity assuming a 50% reduction in setups

Capacity assessment of ability to meet Volvo’s requirements

Suggested ways of improving the operation at Save Batch size reduction Increased capacity Layout changes External

Sundwind’s firm at Save will no longer be able to meet the demands of Volvo. As highlighted in section 4 of the report the production capacity is limited by the current shift setup which the plant operates. Most operations run on a one shift per day basis. If these operations were to be run on a three shift basis the required production volume would still fall short.
By 2002 Volvo plans to produce 65000 units which equates to approximately 1355 units per week. If Save operated on a three shift basis annual production would still be limited to 51312 completed floor units. Operating on a three shift basis would also be costly and produce excess in some areas. This report therefore recommends an optimisation of the current setup which has been both tabulated and represented graphically below:
Operation Setup Runtime Batch Size Time/Batch No. Shifts No. Operators Mins/Week Capacity
Shaping Plywood 170 3.15 2500 8045 2.5 1 5250 1631.448
Painting 0 2.6 1500 3900 1 2 2100 1615.385
Inserting Battens 0 1.5 1000 1500 1 1 2100