Development of CFM56 ballscrew actuators cell

Abstract

The purpose of this thesis is to develop a CFM56 ballscrew actuators cell where analysis was conducted on a fundamental paradigm shift of workflow layout from

conventional process layout to cellular layout production based on customer demands. This shift requires efficient process operated in a high productivity work cell that incorporates principles of good manpower planning, a cellular layout, wastes elimination and continual improvement on work process. This thesis first aims to determine a target desired time between units of production input that is synchronised to customer demands. In a second stage, manpower planning is involved to make adequate and efficient use of the labour to ensure a smooth and successful achievement of the desired time. Next, an effectively cellular layout is designed and implemented such that production work stations are arranged

in sequence and supports a smooth flow of components through the production process with minimal transport or delay. Finally, improvement process is focused on eliminating wastes, improving productivity, and achieving sustained continual improvement on work process. In conclusion, the results of this thesis show the impact of travel and motion which are both non-value added and the wastes which are eliminated. These are measured by utilisation of direct measurement and time study captured in improved process respectively. The target desired time will serve as a benchmark against the overall process time improvements through developed cellular layout and work process improvement. Therefore, this overall achieved process time not only meet customer demands as well as attaining a lean production standard.