While we have a process that can make doors, we need to get the layout to an efficient state and then review BOM labour times.
- First and foremost, the frame drilling and assembly table needs to be finalised.
- SOPs put up in the cell prevalent to their location for each cell bench.
- Tools need to have a home on each of the 4 benches in the cell, within reach at each cell station.
- Frames and glass ready to assemble need locations marked out the floor to pick from stillages.
- Packaging room marked out on the floor
- On each bench I would like us to get in place a 2 bin system to stock at the cell where it is practical to do so.
- Foam pipe lagging covered bars to support glass during assembly on benches to minimise glass scratches and provide location posts in nylon at edges of glass along one side edge only (not both sides as size will vary with each different application) and top edge to avoid edge chips to glass rather then these being in aluminium.
- Special bins folded up to hold long parts that don't fit bins now.
- Proper part number labels on bins and bins laid out similar how they are now to provide a logical sequence of picking parts per their order in assembly sequence and location point position sensible to the position in their assembly to the product.
- Bench shelves re-positioned to provide access to work on product.
- 12 V strip lights installed under bench shelves to illuminate the parts that are being worked on
- Jigs and fixtures mounted in sensible locations within arm's reach
-Smaller jigs wire tapered attached to benches with plastic coated wires.
- Look at line balancing between the 3 major assembly bench areas for glass and frames and decide if what we have now balances and advise what we may further need to design and provide/ make.
- Sub assembly areas set up for actuators, striker loop assemblies, gluing of foam anti-rattle blocks to door lock covers.
- Dedicated trollies for RH and LH segregation of assembled striker loops to brackets
- Areas set for control of non-conforming goods and report back.
- Once we are happy with the layout please have it painted.