Location of the automobile plant
The process of setting up an automobile plant is an enormous undertaking that requires careful planning and execution (Hill, 2002). The location of a manufacturing plant is one of the key factors that contribute to its success or failure. The plant will be strategically located so as to facilitate easy access to labour, raw materials, reliable transport network and subsequently reduce the cost of production. The process of choosing a location will entail carrying out all inclusive feasibility studies in order to determine the labor trends, market trends, weather trends and other factors that affect production. These studies will be carried out over a long period of time and data obtained will be compared to that from similar previous projects.
Design and development the vehicle
The design and development of a new automobile designs was a long and delicate process that can took close to five years before the new designs were ready for production. There is need to identify a gap in the market after which the design team went to work. The first step involved developing computer-aided concepts in line with the customer preferences which had been identified earlier. These concept drawings were then used to come up with life-size models which were subsequently subjected to various tests in order to determine the model’s suitability to its purpose. These tests focused on the vehicle’s aerodynamic performance, safety, comfort, durability, fuel efficiency, emissions, and other critical components. After all the proposed design models have been reviewed, the best performing models were then selected and subjected to further tests. After the designs had met all the industry’s requirements, the go ahead was given to begin production.
Plant layout design
The plant layout will consist of a U-shaped assembly line similar to the one used in most Japanese factories (McAlinden et al 2003). This setup has several advantages compared to a straight line assembly (Klier et al, 2004). This includes staffing flexibility and balance where the U-shape facilitates easy movement to different workstations. It also allows the balancing work among operators depending on the labor demand. Handling ensures that the delivery of materials is easy and convenient. Passage will be implemented, where curved assembly lines facilitate easy crossing to the other side without interrupting the process. Teamwork will utilize a semicircular array which will bring teammates to interact with each other more easily.
The plant will also utilize a mixed model line balancing similar to the one utilized in and the main objective for using this approach is to enable us to meet the demand for a variety of products that we plan to offer to our customers. Using this setup we will be able to produce different models on the same line in an alternating sequence. This setup also allows technicians to exchange work elements and the management to regulate the number of operators. According to Monden (1998, p. 208), “The production per day is averaged by taking the number of vehicles in the monthly production schedule classified by specifications, and dividing by the number of working days.”
Effective product layout design
The product layout determines the flow of resources within the assembly line. The key considerations when designing the layout include the cycle time, the number of stages and how they are arranged, the time variation for different tasks and how the layout is balanced. The machinery and equipment used in a product layout are positioned at strategic points of the assembly line through which every product passes in a pre-arranged sequence. In most cases, the sequence is clear, predictable and controlled from a central point. Modern automobile production lines use flexible manufacturing systems (FMS) which are an integrated system of computer machines or robots that are pre-programmed to perform a series of repetitive actions (Metters and King-Metters, 2003). As a result even a slight change in timing can lead to inefficiency and huge losses. Perfect coordination is therefore a key factor to achieving an efficient manufacturing operation. In addition the product layout design is a long term undertaking which should be carefully planned and implemented due to the financial implications involved.
Project manager’s job description
The key role of the project manager will be to coordinate every aspect of the project. This includes planning, implementation of the plans and the completion of the project within the set deadlines and budget allocations. The project manager will also oversee the management of resources (people and materials) so as meet the project’s deadline. Specific responsibilities will include defining the project scope and goals that support it in partnership with senior management and interested stakeholders. The manager also creates project plans and other necessary documents while ensuring that project expectations are successfully communicated to teammates and stakeholders in a timely and clear fashion. The manager also estimates the resources and participants needed to achieve project goals and drafting and put forward budget alterations as well as recommending budget changes. The manager should also entrust duties to appropriate personnel, identifying disagreements within the project team and resolving them. It is also the manager’s duty to identifying and managing project dependencies and critical path to be followed. Finally, the manager may develop and deliver progress reports, proposals, requirements documentation, and presentations while identifying potential crises within the project plans and devising contingency plans.
Project management
The project management team under the leadership of the project manager will undertake the development of project plan. The involvement of all the team members is the key to achieving the overall goals of the project. The development of the plan will be carried out over several weeks during which the team members will deliberate on the various aspects of the plan. The final plan should include a road map complete with clear milestones, a realistic timescale, detailed report of resource requirements, a validation of the estimated cost and an effective early warning system. The team will also draw upon experience from similar projects to formulate the project plan. This will enable the team to identify the possible problem areas and be able to make the necessary modifications. A project management tool to be used is a work breakdown structure which will be used to divide the project into several tasks and sub-tasks in order to improve efficiency. Critical path analysis is a technique will be used to identify tasks which must be completed on time so that the project can be completed on schedule. A CPA will also enable the team to determine the minimum time required to complete the project.
References
Hill. T., (2002). Manufacturing Strategy: Text and Cases. 3rd ed. New York: McGraw-Hill,
Klier, T., Paul M., & McMillen D., (2004). Comparing location decisions of domestic and foreign auto supplier plants. Federal Reserve Bank of Chicago, working paper, No. WP–2004–27.
McAlinden, Sean P., and Kim Hill, (2003). The Market Renewal of Major Automotive Manufacturing Facilities in Traditional Automotive Communities, Ann Arbor, MI: Automotive Communities Program, Center for Automotive Research, August.
Metters. R., King-Metters. K., & Pullman M., (2003). Successful Service Operations Management. Thompson South-Western
Monden. Y (1998) Toyota Production System: Practical Approach to Production Management (Atlanta, GA: Industrial Engineering and Management Press, Institute of Industrial Engineers, p. 208.
