DCE is based on the north eastern outskirts of Leicester, is part of the
BTR group and manufactures Dust Control Equipment (similar in concept to
large vacuum cleaners) for industry. The company employs approx. 500 people
at Leicester, having subsidiaries worldwide.
The objective of the project, was to construct a component Data Base for
the sheet metal work processed by the factory. Leading onto a Computer
Simulation Model of the Cut/Punch/Fold operations carried out on this work.
The work was to be processed in a "Family" order, similar gauge and shaped
work being processed in a set order, to minimise the setting time between
jobs. This was achieved, using LOTUS 123 for the Data Base and PCMODEL
software by Simcon Ltd. for the computer simulation.
With a change in Production Control management came a complete change in
Philosophy, towards that of MRP 11. This change was mirrored by the project
enabling actual weeks production loadings to be modelled. The comparison of
the Family Part Concept/ work processed by gauge(scheduled)/ Kanban
processing Iogic/ actual factory production was undertaken.
Work processed by gauge was found to be the most effective method of
production. When the comparison with the
wks) was made; the simulation(2.5 wks)
be the most effective method of
methodology used by the factory(6
was found to be 59% quicker to
completion of a weeks' work. Upon investigation the following points were
found to contribute to the discrepancy in times: a lack of rigidity in
processing the work, method of employee payment, factory layout, working
practice and work station ergonomics.
A Master's Thesis. Submitted in partial fulfilment of the requirements for the award of Master of Philosophy of Loughborough University.