Problems in parts & units supply to product line


Assembly lines in factories sometimes develop problems like uneven parts or wrong parts supply due to various reasons. Studies were made by Industrial Engineering experts In order to develop an understanding of the situation, The expert could identify the problems and other interruptions as outlined below:

1. Obvious problems: Unnecessary parts are mixed in, necessary parts are stored in the wrong places, and there is an insufficient supply of parts.

(a) Parts and units are not all stored in the same place. There is often a shortage of these parts and units.
(b) There are other things besides the necessary assembly parts and units on the supply shelves, so they are always full.
(c) Pallets with used tools and small number of parts and units are left on the shelves.
(d) Things are left in high, improper places.
(e) The wrong parts an units, or too few, are often used to make the wrong sort of assembly, and have to be reworked. This was the situation. Next they examined the losses being incurred.

2. Occurring losses : Decreased production, cost of extra parts in stock, and additional interest

(a) Time spent by worker looking for parts and units means a decrease in production (loss of processing costs, added –value etc ) , plus workers have to walk distances looking for things and they get tired.
(b) Time spent on repairing mistakes means less time for production (loss of processing costs, added-value etc )
(c) There is added cost for maintenance and interest on extra stock. Next, Gupta with the other workers about why the problems in 1) occurred, and then organized the causes as follows.

3. Causes of loss: Supply shelves are not supplied properly and unnecessary items are not cleared out, there are no sections or specified amounts for items to be stored.

(a) There are no set sections for what is to be stored in which place and no specified amounts.
(b) Some things are left on a level that I too high to reach.
(c) The order in which the items are delivered form the warehouse does not always match the order in which things are needed. Necessary items are stored too high too reach, the same type of part is left in various different places, there is no way to differentiate between necessary and unnecessary things.
(d) There are no dividing boards, so nobody knows how much space can be taken up.
(e) The transporters, under direction of the warehouse, unload items on any available space. Also transporters have no directions as to what should be taken away and only take away empty containers.