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Ernie Ball Guitars Woodshop Facilities Redesign

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Ernie Ball Guitars Woodshop Facilities Redesign ERNIE BALL GUITARS WOODSHOP FACILITIES REDESIGN by CAMERON LEA SCHLEMER A senior project submitted in partial fulfillment of requirements for the degree of Bachelor of Science in Industrial Engineering California Polytechnic State University San Luis Obispo Graded by: ________________________ Date of Submission: _____________ Table of Contents Table Of Figures....................................................................................................................................... 2 Executive Summary ................................................................................................................................. 3 Introduction ............................................................................................................................................ 4 Background ............................................................................................................................................. 6 Literature Review .................................................................................................................................... 7 What is facilities design?...................................................................................................................... 7 Why do a facilities design?................................................................................................................... 8 How to do a facilities design? .............................................................................................................. 9 What are the objectives of a facilities design?.................................................................................... 10 How are guitars/bass manufactured? ................................................................................................ 11 Design ................................................................................................................................................... 14 Define Departments .......................................................................................................................... 16 Define Relationships .......................................................................................................................... 18 Develop Alternative Layouts .............................................................................................................. 20 Methodology ......................................................................................................................................... 23 Results .................................................................................................................................................. 26 Economic Justification ....................................................................................................................... 27 Implementation ................................................................................................................................. 28 Conclusion............................................................................................................................................. 30 Appendix 1: Manufacturing Procedures ................................................................................................. 31 Appendix 2: Original Flow ...................................................................................................................... 33 Appendix 3: Department Definition ....................................................................................................... 36 Appendix 4: Relationships ..................................................................................................................... 38 Appendix 5: Layout Development .......................................................................................................... 39 Appendix 6: Evaluation .......................................................................................................................... 44 Appendix 7: Project Management ......................................................................................................... 47 Appendix 8: Works Cited ....................................................................................................................... 48 Table Of Figures Figure 1. Original Flow ........................................................................................................................... 15 Figure 2. CNC Machine Location ............................................................................................................ 17 Figure 3. Neck Activity Relationship Diagram ......................................................................................... 19 Figure 4. Body Activity Relationship Diagram ......................................................................................... 19 Figure 5. Alternative C: Separated ......................................................................................................... 22 Figure 6. Alternative B: Least Forklift Travel ........................................................................................... 22 Figure 7. Alternative A: Least Change..................................................................................................... 22 Figure 8. Flow to Travel Transition ......................................................................................................... 25 Figure 9. Original Neck Manufacturing Flow .......................................................................................... 33 Figure 10. Original Neck Manufacturing Flow......................................................................................... 34 Figure 11. Original Combined Manufacturing Flow ................................................................................ 35 Figure 12. Original Departments ............................................................................................................ 37 Figure 13. Body Space Relationship Diagram.......................................................................................... 38 Figure 14. Neck Space Relationship Diagram.......................................................................................... 38 Figure 15. Raw to Blank Department Layout .......................................................................................... 39 Figure 16. Body Fadal Department Layout ............................................................................................. 39 Figure 17. Trace, Kiln, Store Department ............................................................................................... 39 Figure 18. Layout Fretwork Department Layout ..................................................................................... 39 Figure 19. Alternative A: Least Change Layout ....................................................................................... 40 Figure 20. Alternative B: Least Forklift Travel ......................................................................................... 41 Figure 21. Alternative C: Separation....................................................................................................... 42 Figure 23. Alternative B Flow ................................................................................................................. 43 Figure 22. Alternative A Flow ................................................................................................................. 43 Figure 24. Alternative C Flow ................................................................................................................. 43 Figure 25. Project Gantt Chart ............................................................................................................... 47 Figure 26. Work Breakdown Structure ................................................................................................... 47 Executive Summary This report details a facilities design for Ernie Ball’s guitar and bass guitar manufacturing facility in San Luis Obispo, CA. Specifically, this project will redesign the layout for the Woodshop, the largest of the 5 manufacturing cells in the facility. This project was completed using the Systematic Layout Planning procedure and focused mostly on phase II and III in which the specifics for a layout are determined, however, space requirements were not evaluated as it was not within scope. The first step was to develop departments in the facilities, two master departments were identified for the neck manufacturing process and the body manufacturing process. Within each of these, smaller departments were identified, five in the body department and nine in the neck department. These departments were then organized within the walls of the facility using an Activity Relationship Diagram. Three alternative layouts were generated. The first is called Alternative A: Least Change, then Alternative B: Least Forklift Travel and finally Alternative C: Separated. These layouts were evaluated according to metrics developed with input from the client. Analysis determined that Alternative A: Least Change was the best choice. There is a cost of $2400 associated with implementing this change, and with a savings of 460 feet, it will be paid back in 9 months. Introduction This project, in partial completion of degree requirements for a Bachelors of Science in Industrial Engineering, has been performed at Ernie Ball, Inc., a company whose electric guitar and bass manufacturing
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