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Lean Manufacturing. Lean Production System Mapping and Development Saginaw
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Submitted by bzchlz on June 20, 2008
Category: Miscellaneous
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Lean Production System Mapping and Development
Saginaw Metal Casting Operations:
Joe Ruder
Winter 2007
MFGO 633 Project #2
June 15, 2008
Learning Site: Saginaw
Site Code: 43
Table of Contents
1. Introduction
2. Value Stream Map – Current State Summary
3. Value Stream Map – Future State Summary
4. Recommendations
5. Conclusion
6. Appendix – Value Stream Maps
Introduction
Within the Precision Sand aluminum casting process of General Motors Powertrain, there is a consistent effort to continually improve the manufacturing process. Saginaw Metal Casting Operation (SMCO) is in the middle of implementation of the Global Manufacturing System (GMS) in their quest to become a leaner manufacturing facility. GMS is a similar system to the Toyota Manufacturing System. The elimination of muda is the objective of the SMCO organization.
This paper will primarily focus on the Liner Delivery System within the Precision Sand process. The product team receives steel liners from our supplier MPM on a daily basis. There are two types of liners in our current process. We utilize 5.3L and 6.0L liners to build the castings required by our customer, Romulus Engine Assembly.
The liners are required to be baked and then inserted into a sand core within 72 hours to maintain quality specifications. The sand cores are assembled into packages by nine robots and then transported by self guided vehicles to the cast line. The liners are received in pallets containing 288 liners which can produce 48 castings. The department currently produces 900 castings per day but has the capacity to do as much as 1800 castings.
The liners are by far the most expensive aspect of the entire process. The cost of liners is more than 64 dollars for each casting. In additions the liner thermal...
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