PLAN: COSTS ANALYSIS AND LOSSES ANALYSIS (CD) FOR THE MANUFACTURING PROCESS (WO) AND FOR THE HANDLING PROCESS (LOG)

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In this first part (PLAN) were analyzed the losses in the assembly process area so as to organize the activities to reduce the losses identified in the second part of the analysis (DO). Object of the study was the Mechanical Subgroups ETU - Elementary Technology Unit (in a part of the Cassino Plant Assembly Shop). The aim of this analysis was to identify a program allowing to generate savings policies based on Cost Deployment:

In fact, in general a production system is characterized by several waste and losses (MUDA), such as:

It is important to give a measure of all the losses identified in process examination. The data collection is therefore the “key element” for the development of activities of Cost Deployment. Here below in Figure 1.7 an example of losses identified from CD from the Assembly Shop is shown and in  Figure 1.8 is shown an example of CD data collection regarding NVAA (Non-Value-Added Activities) for WO (for this case study we excluded check and rework losses) in the Mechanical Subgroups area. Finally Figure 1.9 shows Analysis of losses Cost Deployment.

Figure 1.7 Analysis of losses Cost Deployment – Stratification of NVAA losses for Mechanical Subgroups ETU - Elementary Technology Unit (figure highlights the most critical workstation)

 

Figure 1.8 Analysis of losses Cost Deployment – Pareto Analysis NVAA Mechanical Subgroups ETU - Elementary Technology Unit 

 

Figure 1.9 Analysis of losses Cost Deployment – Pareto Analysis Line Balancing Losses or Insaturation on Mechanical Subgroups ETU - Elementary Technology Unit