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Cleaveland/Price began supplying renewal parts for Westinghouse switches in 1975. Since those humble beginnings Cleaveland/Price is now a major manufacturer of high voltage disconnect switches and automation equipment. The company is located in Trafford, PA (SE Pittsburgh) and it employs about 150 salaried and hourly employees,
Situation:
Cleaveland/Price’s growth is limited only by its production capacity. Currently running 2 shifts in a 90,000 square foot foot facility, they realized it was time to start focusing on manufacturing methods to gain productivity and capacity. On the drawing board is a 30,000 square foot expansion, but linear growth alone will only be a temporary solution to capacity problem. With that understanding Cleaveland/Price wanted to do everything possible to maximize their existing capacity. Specifically, the company had goals of increasing throughput by 20% in 2008 without any increase in production floor space or any significant increase in resources. They also hoped to reduce lead times from their current 18-20 weeks down to 14-16 weeks. |
 Objectives:
- Assess the applicability of simulation technology for a redesign of the Vertical Switch Assembly area.
- Develop simulation models of both current and future-state processes to show the benefits of adopting “Lean Production” concepts in the Switch Assembly area
Solution:
ProModel conducted an initial, on-site assessment to understand how simulation could help achieve the production gains sought. They began by documenting the process and talking with production operators to gain a full perspective of the current-state process.
ProModel used a two phase approach, using the tools Process Simulator and ProModel. Process Simulator, a Microsoft Visio-based tool, was used first to document the process and create quick estimates of process capability, such as throughput, cycle time, inventory levels and resource utilization.
Next, ProModel’s flagship software ProModel, was used to create 3 separate models:
| 1) Current-state batch assembly process |
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2) Future state Lean “Flow Line" |
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3) Future state Lean process with better line balancing to allow a 20% increase in throughput.
Results:
The current-state model was found to accurately represent the performance of the existing Vertical Switch Assembly process. In addition, the future-state model using a Lean “Flow-line” concept proved to be far more efficient than the current batch process. The results of the future-state model showed that a 20% improvement in throughput was indeed possible, while also achieving a 67% reduction in pole unit cycle time, a 50% reduction in floor space requirements, and elimination of the partial second shift.
Next Steps:
Before implementing the future-state solution on the floor, Cleaveland/Price management plans to add the remaining Switch types to the flow line model and tweak the workstation task assignments to ensure the smoothest possible transition to a live system. Upon completion of this additional model scenario, the changes to the floor will be made, starting with installation of I-Beam rails and specially designed “skates”, upon which each unit will travel. Beyond this, future Kaizen events will be held to add feeder lines for production and delivery of sub-components.
Ultimately, Cleaveland/Price management envisions conducting other simulation-based “Virtual Kaizen” events for the ADMO™ assembly area. Long-term projects where Lean concepts may be applied include Fabrication, Engineering & Design. |
